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Okay ran into something I had never done before recently. Needed to cut .02 chamfer on parts with Ball Endmill. It took me a little bit to figure out how to accomplish the task and it takes some work. I tried many different surface toolpaths and could not find one that handled the process very well. I can take blend and get about the closest, but still not exactly what I wanted. I wanted a 3d Contour pass that would cut right in the center of the chamfer as it came into contact with the part. The 3D Chamfer with a Ball Endmill works great when the surface is normal to the plane. Thing it with clamps and everything it would have required hanging a 1/4 endmill 2.25 out of a holder. With kicking the part off 60 degrees on each side of this part I can get to everything in each index position with only 1.25 sticking out of the holder. I have cross holes, counter bores, pockets and then outside shape of the part that all gets deburred. Sorry cannot share the part, but it is an extrusion with all of this going on. The lengths get cut which create a burr and all the other work. Parts are solid models without the chamfers on them. They will not chamfer all the way and I have had to create some geometry to achieve what I am after. Here is my process and hoping someone has figured out an easier way.

 

#1 Move Solid to Level by itself.

#2 Create all the chamfers I can on the solid, then fillets where chamfer fails.

#3 Make new Level for surfaces from Solid that are the chamfers.

#3a Create chains on the edges of the radius that is same edge if I could create the chamfer on the solid. (Side not Be Awesome if Surfaces could create chamfers)

#3b Create lines to close the shapes made along each of the edges.

#3c Create Net Surfaces that are what I should have got from the solid had it not failed to create them.

#4 Take all the surfaces that are where they should be from the model and offset them all the Radius of the Ball Endmill being used.

#5 Create a New Level Chains of Chamfer Pass

#6 Use the Create/Curve/Dynamic Curve on each of the offset surfaces with them unshaded since the unshaded surface has a center line to it.

#7 Once they are all create turn off the surface level and then fix all the gaps. I may use a line, extend a line, trim with 2D from a different view and my favorite one Create/Spline/Create Blended Spline.

#8 I then use my 60 or -60 deg T-Plane to make my toolpath from using 3D contour with incremental depth. Negative amount which is the radius of my endmill. Control Set to tip so the operator does not have to think about setting the tool different than others.

 

This process is working very well, but on each part I may have upwards of 2 hours doing all of this work. I have tried all type of CAD tricks none seem to create the curve right. I have tried every thing I can think with surfacing toolpaths none got it exactly right. I have tried scaling the model bigger to create the surfaces in the right spot. I have tried fitting shapes. Little things like on holes that makes it go quicker is offset the surface. Create Curves on the edges. Then draw a perpendicular line from each edge in 3 places. Then come back and draw a 3 point circle using the mid points of those 3 lines. Do the same on the straight areas and again draw a line from the mid points. Areas where they are odd shapes still having to draw them and it is taking a bit of time.

 

I hope some people who might have done this and know an easier way might help out. As always thanks for any ideas or suggestions you might have.

 

Oh yeah sorry for the length those that know me accept I talk to much.

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Ron, if you did not find the solution you want, it's because is way too complex or unsolvable. :D

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hey ron

did you try the chamfer option insider the create surface fillet option

post-9383-0-40610600-1392248958_thumb.png

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Ajmer never seen that and does help create some of the surfaces I have been doing one by one. They also offset much nicer than the net surfaces I was creating. Thanks I really appreciate you pointing that out to me. :thumbsup:

 

Though this method only likes one 1st surface and one 2nd surface. Doing more than that is complains, but better than where I was.

 

Solidworks choked chamfering these features as well so I know it is the shapes I need to do that is creating the issues here.

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Hi Ron,

 

Have you tried either Flowline or Multi-axis Flowline, using the "Rib Cut" option? With the Rib cut, you can force a ball endmill to make a single pass down the center of the surface. Not sure if that would save you time with creating the toolpaths or not...

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Hi Ron,

 

Have you tried either Flowline or Multi-axis Flowline, using the "Rib Cut" option? With the Rib cut, you can force a ball endmill to make a single pass down the center of the surface. Not sure if that would save you time with creating the toolpaths or not...

 

Colin, am open to anything. I will try it and report back. Thanks for the suggestion. :thumbsup:

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Curve 5 axis, radial offset to 1/2 the radius, comp to surfaces, and use negative stock to leave. you still get lead in/lead out. you still get overlap on closed contours. you still get multiple passes so you can a rough and a finish on multiple chains in one toolpath. depending on what you are looking for you typically don't need to create any surface fillets/chamfers just use existing wireframe.

 

 

HTH

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Colin didn't work reports surface conflict.

 

Roger, I started with that, but since they do not have 5 axis on the sim was stuck with trying to make 3D contour work. Thanks for the suggestion again help is appreciated.

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