All surfacing TPs have filters, plus all the dynamic TPs That's actually pretty good, having to deal with small memories, that's probably the best you can do. What material is the part made of?

You had one dynamic coming in from the inside and one from the outside. The way I did it is one operation with the 3/8s tool and setting the inner diameter as air, using the 1/2 then the 3/8s is a waste of time IMO. Also, I don't mess the filter tolerance. See the thumbnail to see how I do it. I use the same filter settings for dynamic operation and for the flowline

Colin, Thank you. It was set to 80%. Changed to 100% and fixed it for now. Now I know where to look if it comes back again.

Trying to upload and it wont let me. First, use only the 3/8 tool and do a dynamic with the big circle set as AIR, you can do it in one shot with one tool, forget the 1/2 endmill. - To do the radius use a flat endmill with the Flow Line, it will leave a sharp corner. It works, I've done it dozens of time. One more thing, use filters. Don't forget the filters. Did I mention filters? Don't be afraid to do surfacing with flat endmills. IF I could upload the file it would help you more.

Each toolpath has depth settings in them to decide a area of place you want to cut. Part is 2.000 tall and cutting from .0 to -.2 creates 1000 kb of code. Then you make one toolpath that cuts everything and you then copy and paste it 10 times. Then in each toolpath you change the depth settings to cut just that section of the part in that. Now if .2 of area is too much then just change the settings to limit how is being cut and then just track the correct over lap to get what you need. Go to a 1/4 ball endmill for the finish you need.

Does the part have real sharp corners? I have done parts like these over the years and they never have a real sharp internal corner. What is the max radius allowed? Grab a Bull endmill with that Radius and look at using it. What kind of machine is this? I see 4 Axis defined in the File so with that you are limited in your choices of toolpaths. I might old school this and just do are Surface Finish Contour from the plane you have defined and call it a day. Break each depth section into the machine size limits and have tapes A-Z, AA-AZ, BA-BZ and such until you have made a complete program. Right click on each section and use the rename NCI to make them all different program names for posting and done. I normally make Toolpath groups for each tool or tape, but sounds like people could care less about organization and just get it done. What is the profile tolerance on the 5" Radius area or the .5" radius Area? What is the surface finish requirement? Tape A to Tape Z Tape AA to Tape AZ Tape BA to Tape BZ Right there is 76 Tape names and easy for anyone to follow and track and they run them on the machine.

I agree with balnh, helix mill if possible rather than plunge.

Much better solution than mine, I didn't think they had a muti-axis license!

Morph between 2 curves will be your friend here... BUT......you have program size issues.... I don't have time this morning but I might draw lines along those vanes and use a project toolpath to rough it out...you should have some better filter options that way.

Look at using a Scallop toolpath with a boundary chain to limit the tool. Use a small diameter ball nose to limit the corner rads.

@AGreen5 In-House Solutions has the ability to modify the .machine file for you. If you want to reach out to us we can discuss options for making the changes you require. Send me a PM and I can provide you with the email address to reach out to for these modifications.

when I run into this, I decline to delete the corrupt tools then make new tools and replace the corrupt tools

This... ^^^^^^^^^ I've got a customer with probably 30 Mazak VMC's. They do a lot of part family type work. They still do all their programming offline. Revision control, process control, tool library control, etc... in this day and age, conversational programming for all but the simplest of parts just doesn;t make a whole lot of economic sense. At least from my seats.

If I had CAD/CAM at my disposal, I would NEVER use conversational on a mill except as an ABSOLUTE last resort. That just defies all logic IMHO.

Try these numbers/places; https://us.mitsubishielectric.com/fa/en/about-us/locations

Yes. That's exactly where you should make your edits. There is logic that says "if the value of 'cantext$' is greater than 5", then output it as a M-Code. You can modify that output block, as needed, to capture different conditions. Here is that same Block, modified to output what you wanted: pcant_out #Canned text - build the string for output #Assign string select type outputs if cant_pos < three, #cant_pos indicates canned text output [ if cantext$ = three, bld = one if cantext$ = four, bld = zero #Build the cantext string if cantext$ = one, strcantext = strcantext + sm00 if cantext$ = two, strcantext = strcantext + sm01 if cantext$ = five, strcantext = strcantext + scant5 if cantext$ = 6, [ pbld, n$, "G00 G30 P1", e$ pbld, n$, "M04 S5000", e$ pbld, n$, "G04 P1", e$ ] if cantext$ > 6, [ strtextno = no2str(cantext$) strcantext = strcantext + strm + strtextno ] ]