So I went with 11,000 rpm @ 38.0" ipm and .280" ap(depth of cut) Min toolpath radius of .005" It worked GREAT! Thanks for the support to give me the confidence to try something out of my comfort zone.

So when you move into both interior and exterior corners, unless they have less material than the entry and exit areas you will get points along that corner where the chipload spikes. As I said previously, Waspalloy is unforgiving so even a 12µm spike in chipload in a short distance on an interior corner will snap an endmill easily. To lessen the effects you can pretreat the corners by either drillng or milling out interior corners to VERY near net finish dimension (within 10-15µm) or by using the corner pre-treatment option in the HST toolpaths for the exterior corners. Constant, reliable engagement is your friend on the super-alloys and hardened tool steels.

Constant chip load, no it doesn't. Constant engagement angle, yes. I'm not exactly sure why there is not an option to keep a constant chipload or maybe even MRR constant, I assume it is a patent infringement on someone elses toolpath as it seems like a no brainer to have this option in Dynamic. As is, we are over feeding on internal features and under feeding on external. ...I think there is mention in a posting somewhere here of handling this in the post processor. No idea how well it works as I've not tested it. Of course, not all will agree with me so I leave you this...

I really with the plane and level managers could be set up to operate like the operation manager where levels and planes could be grouped by operation and expanded or contracted as needed. When I have a part using 40-50 levels and 30-40 planes spanning 5-6 operations it can be a pain getting the right plane, especially if they are added out of order. I know in the grand scheme of things this isn't that complex. I could only imagine some of the huge files some people deal with. Just my $.02

Check out this thread for some information on modifying your Chip Load "on-the-fly", by looking at the Arc Radius of the Tool, Path, and the "Linear Feed at Tool Center", versus "Linear Feed value at the Tool Periphery".

There is a generic Haas 4 axis post available on the Mastercam.com Tech exchange It supports both horizontal and vertical 4 axis Haas mills Tech Exchange - Home (mastercam.com) You will need to create and account on Mastercam.com to download it

Thanks for this man. My vision thanks you as well

IDK why they don't add Circular feed compensation to the dynamic toolpaths. Surfcam's true mill had it 15 years ago and by now all related patents must have expired.

#region Tool change / stage tool ptlchg$ #Tool change pcuttype toolchng = one if mi1$ = one, #Work coordinate system [ pfbld, n$, *sg28ref, "X0.", "Y0.", e$ pfbld, n$, sg92, *xh$, *yh$, *zh$, e$ ] inhibit_probe$ if prog_stop = 1, pbld, n$, *sm01, e$ if prog_stop = 2, pbld, n$, *sm00, e$ pcom_moveb pcheckaxis c_mmlt$ #Multiple tool subprogram call ptoolcomment comment$ pcan result = newfs(15, feed) #Reset the output format for 'feed' # Changed by DG 02/01/2022 # Same deal - need to trap and inhibit tool change # We will issue a hard stop here as this subroutine is called for toolchanges # Other than the first # pbld, n$, *t$, sm06, e$ sopen_prn, "REMOVED A TOOL CHANGE - STOPPING ", *t$, sm06, sclose_prn, e$ pbld, n$, sm00, e$ pindex sav_absinc = absinc$ if mi1$ > one, absinc$ = zero if use_rot_lock & (cuttype <> zero | (index = zero & prv_cabs <> fmtrnd(cabs))), prot_unlock if convert_rpd$, pconvert_rpd # Changed by DG 02/01/2022 # Same deal with spindle speed and mixing other codes with G0 #pcan1, pbld, n$, [if gcode$, *sgfeed], *sgcode, *sgabsinc, *sgplane, pwcs, pfxout, pfyout, pfcout, # [if nextdc$ <> 7, *speed, *spindle], pgear, [if gcode$, *feed], strcantext, e$ pbld, n$, [if nextdc$ <> 7, *speed, *spindle], pgear, e$ pbld, $n, *sgabsinc, *sgplane, pwcs, e$ pcan1, pbld, n$, [if gcode$, *sgfeed], *sgcode, pfxout, pfyout, [if gcode$, *feed], strcantext, e$ if use_rot_lock & cuttype = zero, prot_lock pbld, n$, sg43, *tlngno$, pfzout, pscool, pstagetool, e$ absinc$ = sav_absinc pbld, n$, sgabsinc, e$ pcom_movea toolchng = zero c_msng$ #Single tool subprogram call !xnci$, !ynci$, !znci$ Done. Thanks!

Waspalloy is VERY unforgiving material. . Plunging even 25μm and your tool is as good as cooked. You have to ramp in Z any transition from one depth to another. On another note, it is VERY possible that an inside corner transition created by arc filtering caused a sudden increase in chip thickness thus blowing up your tool. Of all the materials I've cut, Waspalloy is in the top 3 or 4 most difficult to cut. By difficult I mean that I have to think about every motion in the path and it's potential effect on the tool. HTH

There is nothing more gratifying to me than hearing that my help was well received, and able to help someone overcome an obstacle. I can't payback all the help I've received to get me to where I am today, even if I had a hundred lifetimes, so my goal is simply to pay it forward.

Interesting. I will check them out next time I have a need. I've been using some Garr VX-7 tools in titanium, invar, and heat treated stainless. The coating they have on those tools is pretty amazing. Blew every other tool I tried out of the water as far as tool life goes.

These tools have through the spindle coolant directly in the flutes and if want to keep long stringy chips under control for roughing then you are already using serrated edges. It might look like old a school rougher, but trust me the 4th flute in Aluminum with the TSP is a game changer. Want to bury this tool in a full slotting application give it a shot. Want to start thinking about 60% step over at 100% DOC using HST toolpaths this will be tool I will give it a try with. We all think only 3 flute for clearing out chips, but these tools with the polished gullet areas are impressive to watch cut. The TSP ability right at the cutting edges is the real difference. With TSP holders we get it above the tool, but with these it is in 2 places right at the cutting edges and at the tip.

One thing to keep in mind is the TIR of your tool a Ø1 endmiil running out .002" is .2% of the tool diameter and 10 to 20% of feed per tooth a Ø.093 endmill running out .002 is 2.15% of tool diameter and 2 to 300% of feed per tooth this will almost certainly fail

Hit Clear Colors first.... When you move something it turns purple...that's the "Result" color If you copy it, the one you copied turns "Red" the one you copied turns "purple"... Clear Colors will remove those colors and set the geometry back to the color it is define at..

And now they blend in nicely with my grey background so I can hardly see them at all. Definite downgrade for me.

Kind of. Volumill will adjust the feed-rate based on external/internal arcs. Mastercam has a modifier in the filter in 2018, in the 2d contour tool paths to adjust the feedrate on arcs, I did not see it in any of the Dynamic tool paths however. I still think machines achieving the actual programmed feedrate is more of a problem than not adjusting the feedrate for Arcs. One extremely talented guy on here was working on a post to make the adjustments for arcs, but Mcam doesn't really have it supported IMHO. I think that is solely dependent on what features are being cut. I would be interested in where the 27 percent came from. A boss will have less air cuts if the stock is symmetrical than compared to the same boss when the stock is not even on all sides. Ex. a rectangular boss out of rectangular stock vs. a square boss out of rectangular stock.