REST ROUGHING GOUGE..

[Greg_J]

Good day,

I had a gouge at the machine from a rest roughing program that did not show up in Mastercam's Verify.

Has anyone had this before?

I ran a Surface Rough Pocket with a 3.0" high feed, then a Area Rest Rough with a 2.0" high feed then another Area Rest Rough with 1.25 high feed and that is the part of the program with the gouge. Mastercam showed a perfect part in Verify.

The only thing I can think is that the way the machine interpreted the arc's is different then the my post settings?

I am using a traditional bullnose tool to define my high feed tools and not the new high feed tool which would give me more accurate toolpath.

Any ideas?

I wish I had Vericut.

Thanks,

Greg

[Guest]

The only times I have seen innacurate verify  is if a rapid motion caused the gouge eg.  low retract, or  while combine surface operations and toolpath transform (unsafe).

[Guest]

IIf you turn on your workpiece collision setting in verify do you get a warning?

[Greg_J]

Nope, I shows a good part.

Used the compare functions and it shows correct stock amounts.

[nickbe10]

37 minutes ago, Greg_J said:

Any ideas?

Have a look at your step over : min toolpath radius ratio.

Rule of thumb is min toolpath rad should be at least 2x the stepover. Sometimes with small cutters and stepovers it needs a bit more than 2x.

[Guest]

COLLISION_SETTINGS.bmp

[Guest]

The default collision setting is +-.01 if your gouge is less than that it won't be detected by workpiece collision settings

[nickbe10]

1 hour ago, Greg_J said:

Nope, I shows a good part.

Does the toolpath take off in a fairly large arc?

The min toolpath radius is used for the entry arcs after the ones defined in the Linking Parameters page.

I have no official knowledge but it seems to me that if you use a stepover bigger than the min toolpath rad a whole bunch of intersects and tangencies will be created with short arc segments in between.

When I have encountered this it always looks to me like it has picked a segment and then gone the "wrong way" possibly because it cannot discern the correct direction due to the short arc length, which might be interpreted as a line or spline.

Again this is just a guess as to what is happening. 

[Greg_J]

Peter: It seems that my tolerance is at .006 this gouge is about .100 so I don't think it's that.

As for the arc it not a large arc it's just rolling around a corner into a long straight cut.

As I look into this more it seem like it's not using the correct diameter or nose radius for the tool.

I ran a new program that has been slightly adjusted with tighter tolerances and I had the same result so now I am defining the tool as a High feed tool and filling in all the parameters and I'm going to run this shortly. Hopefully this will fix the issue. 

[Greg_J]

I figured out what the problem was.

The operator used a 1.5 high feed and it should have been 1.25 high feed.

I knew it was the tool geometry.

 

 

 

[Guest]

Ouch well at least it wasnt your verify the culprit.