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Showing content with the highest reputation on 06/12/2020 in all areas

  1. On your Matsuura you want to ALWAYS use the High Speed Modes. Make sure to use the correct High Speed Mode for the type of machining. 2D = G131P... 3D = G131M... Rotary =G131 F... Canned Cycles = G131 D1 In each mode (other than drilling) there are 3 settings. 1=Roughing/General machining 2=Semi-Finish/Finish 3=Fine Finish. Or 1=Speed Preference to 3= Accuracy Preference. You should be able to hold single digit micron accuracy on a 2D profile using G131P3 with arcs (provided the CAD is good) or line segments. Are you using CAMplete?
    3 points
  2. In those cases i have had really great luck kicking the part at an angle and using a ball em to surface the corner. Yes it does take longer but given you have a machine that has 5x capabilities and it is really tight (center of rotation is dialed in ) then it works great. Blending two tools isn't ideal but again, if the machine is tight then it's no issue. Also have used a ball em of equal radius as the part fillet and used multiaxis morph to drive the tool using 1 pass (determined by number of cuts, area type) That is my preferred method because the surface finish is beautiful especially in aluminum. Only using 3 axis is preferred but if the machine is tight then use the features you paid for.
    2 points
  3. My suggestion would be to helix interpolate your corners then do your finish passes, or do your it in two depth cuts with a spring at each level. I agree that tool deflection is likely the culprit. That is a way bendy tool. You are at 5xØ if you were to bury the tool up to the flutes, but in reality you are probably at close to 6xØ. I am guessing .850 stickout? You would likely be good if you were at 3xØ or less. As Ron mentioned, take an indicator and check the wall deflection. I would expect on a straight portion with a spring pass you probably have .001" or so. Once the engagement goes up as it will in the corner, you will have much much more. By my math assuming 45 degree helix, you have a pretty even split of 3 and 4 points of contact in cut when you go through the corners. In a straight wall situation, you still have a mixture of 3 and 4 contact points, but more on the 3 side. With less depth of cut you would be in the 1 to 2 contact point, not ideal, might chatter, but won't deflect nearly as much (less than half). All that said, there is also no reason you should not max out your spindle speed to 12000, you could also probably double your chip load and still be conservative. 12k @ 50ipm should be good for a new starting place. Reduce feeds by 50% in the corners. With increase in speeds and feeds you should get it done in the same amount of time. With that machine you should be able to hold very tight tolerances at 50ipm. Much tighter than you are likely seeing for cutter deflection.
    2 points
  4. Why you were called when I saw the machine. Thank you as always sir for chiming in and sharing your knowledge to help others.
    1 point
  5. My condolences @machineimpossible. An NC Format can be configured to take advantage of what you do have. PM me and I can help you get that sorted out. CAMplete is a vital tool IMHO. So, the R-level modes are old school. Not tailored for they type of machining at hand. By using only G05.1 you would be missing out. By using R levels you are missing out. With R, you only have 11 settings period. (R0 through R10) By using P, M or F when combined with the sliders, each mode has 10 possible settings, for a total of 31 setting possibilities. So if you set G131R3, then move the slider all the way to the right, this will give you max precision, activate any and all control contour control functions available on the machine, plus allow you to run arcs for smaller programs. Do this; Poor Man's Dataserver. https://www.dropbox.com/s/wkro1ylu2im5ir5/M198 to Flash Card Procedure - FANUC 30i-31i Updated.pdf?dl=0 Hope this helps.
    1 point
  6. Well I am one that didn't like the other way all the time, but there were times when I did so I would switch back and forth and tried that in 2021 and complained to QC when it wasn't an option anymore. I for one would like it back since I did switch between them. JM2C on it.
    1 point
  7. I had never noticed it there before. I have wished it was turned on though. Just toggled it on in 2019 and will give it a try. I learned something today! It's a good day! Thanks guys!
    1 point
  8. You can disable hst default changes in the settings. I always do because in previous versions changing the dia of the tool used to eliminate entire depth passes
    1 point
  9. That is the funny part is was an option until 2021 and it was removed. Like I said it was the opposite way for years and we could change it. Now we cannot. From 2020:
    1 point
  10. Too much load on that tool. Take a spring pass in the corner using the same speeds and feeds and your part will come into tolerance. All tools move and that tool is deflecting. Want to test my call take a .00005" indicator and run it up and down the corner and see the taper you're getting from top to bottom. I watched a 1/4 ball endmill deflect to almost 30 degrees one time and not break. I was machining a locate slot on a 40 ton turbine housing about 25 years ago on a HBM. 3 other people had tried all of them with 20+ years experience and they all failed. The slot was 6" deep and had to have a .001 tolerance from top to bottom. I took the 2" diameter 6 flute endmill and worked on it for 6 hours. I had 4 different indicators setup to control back lash. I took 12 cuts in the same place and all 12 cuts removed material. It wasn't until the 12 cut that I got the doblocks to go from top to bottom on that shape. Why was that? Tool deflection. The .0065 of material for 1/2" of of material is a lot of material to remove for a finish pass. Try getting a 7 flute endmill and take the same cut the difference will be night and day. Lets teach you some Physics about tools. The cross section of 3 flute tool is about 45-50% of the tool diameter. That means your tool effective strength ratio to length of cut is at 50% of the tool diameter. Your working with .08 diam of tool to fight against push back from the material as it is cutting. Now you have .0065 of material and that is about 8.5% of the effective tool diameter fighting against you to do this with. Now move to a 7 flute tool and you have about 70-75% off the tool diameter to work with. You have a much stronger tool due to the core being a bigger diameter. People always think you must use a 3 flute tool when finishing aluminum. No you don't have to use a 3 flute tool to finish aluminum. I will use a uncoated 5-7 flute tool in aluminum all day long with superior results to a 3 flute tool. Problem is finding them uncoated. Problem is the aluminum will stick to any tool costed with an aluminum substrate and that is the bigger issue doing it than the tool loading up for finishing.
    1 point
  11. "...Makes some for us happy they finally went in this direction and now others want it like it was..." I have to laugh since we just came to the same conclusion in the last couple minutes when I talked to the developer! There is no way to override the new behavior, but we'll consider it ... Reko - thanks for posting.
    1 point
  12. They finally changed the process to what I used as the default for years which was last. Now you don't have a way to change it back to not use last in the configuration settings like they had in previous versions. Makes some fo us happy they finally went in this direction and now others want it like it was. Why software development is so hard.
    1 point
  13. Do a stock model after the milling operations using them as the source operations. Then use the Create Stock Boundary to update the lathe stock after milling operation are done and it will create the correct lathe boundaries from that and you're good to go.
    1 point

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