Simple 4 axis contour help!

[andrewkeisler]

I am having problems with a simple 4 axis contour. I am trying to contour the outside of the part using a 4 inch facemill. I want the facemill to follow a line I have made in the center of the part (layer 1 geometry). I figured a wrapping feature would be the way to go but I have had no luck. Here is the attached file for x4. Thanks so much!

 

Andrew

RSL.MCX

[Brando]

looked at your file and that would be a 5x path that converts to a 4x, i dont have a seat for 5x, also that would require a lead tilt on the face mill to cut around that arc it will leave cusps, which isnt going to leave a nice finish, personally id get a ball mill and surface it or have a corner rounding mill made up thenside cuts and done with it

[Rotary Ninja]

I agree. Face each side then position the rad straight up and surface with a ball endmill. A facemill will not work the way you are wanting.

[andrewkeisler]

It all makes since now with the geometry of the tool as it cuts the arc. The center of the arc would never be cut with the facemill. I appreciate the help guys and sorry I didn't catch it sooner!!

[Rotary Ninja]

I cannot save a Mastercam X4 file but I can show you what I did. Someone else may have a better suggestion, but here ya go...

 

I created a surface using your geometry:

 

I created a Flow 5 Axis toolpath using the following parameters:

[andrewkeisler]

Check this out. I made a solid over laying my part just as you did with a surface. I used a 4 axis rotary path. I had to draw up a flat endmill and use its geometry over the sphere mill since mastercam will only allow sphere mills to be used with a 4 axis rotary path (stupid if you ask me).

 

Tell me what you think.

4AXIS CONTOUR.MCX

[Rotary Ninja]

Sweet! I learned something new

[Jayson Kramer]

Here is a video taking thru X4 doing curve 5axis to get what you asked for.

http://www.ppcadcam.com/curve5xv4.wmv

 

Let me know if this what you are looking for.

[Rotary Ninja]

That would leave a raised area around the radius though because the center of the face mill would not cut that area. Unless you used a center-cutting 4" endmill instead of a face mill.

[Jayson Kramer]

I never said I would do it this way but we were asked how to do it this way.now the logic can be changed and use different tools. I thing it should be done the way some have talked about. face one side flip 180 face other and use ball to surface the rad at A90.

[Rotary Ninja]

That makes sense. We already decided this wasn't going to work though

 

What are you using to create the videos?

[andrewkeisler]

Yeah my Fadal doesnt process 3d code fast enough to consider using a surface path. Besides, I need to spit these out in a few min. vs. 10-20. Here is the completed toolpath. Making 6 of em at once. Before the final contour, a side fixture is placed underneath the parts and they are bolted to it.

REAR SPINDLE LOWER 4X.MCX

[Rotary Ninja]

Very nicely done. Show us a pic of the final part.

[Jayson Kramer]

That makes sense. We already decided this wasn't going to work though

 

What are you using to create the videos?

I use Camtasia.I just set the res that it mad it a little smaller then my wide screen for most and file size.

[Jayson Kramer]

OK I am not understanding the tool one. are you using a 2" ball called out as 1" ball but really using a 2" flat custom.. wow!

[Rotary Ninja]

LOL. Yeah, that is awesome huh.

[andrewkeisler]

LOL. Yeah, that is awesome huh.

 

That was the only way I could use a flat endmill. I had to lable the diameter as 2 inches. I have no Idea why. When I labled it as 1 inch, the tool only showed up as .5 when previewing. I think it might have something to do with the arc of the ball nose that it is wanting to configure for.

 

It might be a month or 2 before I start producing these but I will post pics!

[Rotary Ninja]

I am following this topic. So revive it when you do.

[KMartin]

What is the material the parts are made out of .