Wasted cuts in Optirough

[JB7280]

I noticed I always have lots of wasted cuts in optirough, particularly on top corners.  I'm guessing because technically, there is more than whatever stock you left, and it goes around the corner to trim that off.

 

It looks like, by lying and saying my tool has a sharp corner, I can eliminate these extra passes.  This particular part is 6061.  I understand that it'll leave extra material, and my be an issue on tougher materials.  But, as long as I account for that, it shouldn't cause me any problems, should it? 

 

Or is there a better way?

[Jake L]

I've not heard a good solution to this issue. Programming the tool as a sharp corner is a very interesting solution.

I suppose it'd be possible to modify the model to make a "plus stock" model and run opti rough off that. Depending on your part that could be a LOT of extra work.

If someone has a better way to eliminate these cuts I'd love to hear it.

[JB7280]

9 minutes ago, Jake L said:

I've not heard a good solution to this issue. Programming the tool as a sharp corner is a very interesting solution.

I suppose it'd be possible to modify the model to make a "plus stock" model and run opti rough off that. Depending on your part that could be a LOT of extra work.

If someone has a better way to eliminate these cuts I'd love to hear it.

From looking at the generated stock model, it appears to have eliminated those cuts.  I might not use that approach on something like inconel, or carpenter, but on aluminum, I'm not worried about the little bit of extra material.  

[Leon82]

it rounds the top even with a flat endmill.

if the corner were shart technically it would have more material on it than what you set. there is a setting for stock to leave not to round corners in contour. maybe something similar. or a check box in tool path fillet to make sharp