ok, could be wrong here, But...Doesn't the Surface Rough toolpaths 'assume' full stock? Since the part is already roughed out on an EDM, I would only use Finish paths to complete the job using multiple paths with reduced Stock to Leave as necessary.

That's a feature that He Who Shall Not Be Named b!tched long and hard for....Looks like he got his way.

We've had good luck with Schunk in our 18k spindles.

Apparently, it's Live! click Help/Update Mastercam then when the next window opens click Check Now. Approx D/L time here: 4 1/2 mins

also, you could extend the parting line surface out over the cavity to prevent the tool from rolling into it.

A quick and easy work around is a Scallop path set very shallow, say 0 to 10 degrees to knock down any high spots.

Surface Rest Rough would be one way to do it

I've got 4 open right now...no problems

Mazak Matrix Nexus control errors on lines with parenthesis which occur between HSM paths using same tool. N1 T12 M06 (DAPRA 3/4 BALL NOSE INSERT-HS) (MAX - Z2.) (MIN - Z-2.5541) (TOOLPATH - WATERLINE........) (STOCK LEFT ON WALLS = 0.) (STOCK LEFT ON FLOORS = 0.) G00 G17 G90 G54 X-24.4948 Y2.3054 S5500 M03 G43 H12 Z2. M50 G94 G61.1 ,K80 G05 P2 G01 Z.109 F500. Z.084 F100. X-24.4952 Y2.3051 Z.076 X-24.4963 Y2.3044 Z.068 X-24.4981 Y2.3033 Z.0603 . . Y17.6852 Z-.1982 Y17.6872 Z-.1906 Y17.6884 Z-.1828 Y17.6888 Z-.175 Z2. F500. (TOOLPATH - WATERLINE........) <------Matrix Nexus Control Doesn't like lines with parenthesis (STOCK LEFT ON WALLS = 0.) (STOCK LEFT ON FLOORS = 0.) X-.5962 Y6.6434 Z-.106 Z-.131 F100. X-.5958 Y6.6432 Z-.1391 X-.5947 Y6.6426 Z-.147 X-.5927 Y6.6417 Z-.1548 X-.5901 Y6.6405 Z-.1623 . . N1 T12 M06 (DAPRA 3/4 BALL NOSE INSERT-HS) (MAX - Z2.) (MIN - Z-2.5541) (TOOLPATH - WATERLINE........) (STOCK LEFT ON WALLS = 0.) (STOCK LEFT ON FLOORS = 0.) G00 G17 G90 G54 X-24.4948 Y2.3054 S5500 M03 G43 H12 Z2. M50 G94 G61.1 ,K80 G05 P2 G01 Z.109 F500. Z.084 F100. X-24.4952 Y2.3051 Z.076 X-24.4963 Y2.3044 Z.068 X-24.4981 Y2.3033 Z.0603 . . Y17.6852 Z-.1982 Y17.6872 Z-.1906 Y17.6884 Z-.1828 Y17.6888 Z-.175 Z2. F500. G05 P0 <--------------------------------------Need to add this G64 <-------------------------------------------And this (TOOLPATH - WATERLINE........) (STOCK LEFT ON WALLS = 0.) (STOCK LEFT ON FLOORS = 0.) G94 <-----------------------------------------Maybe this? G61.1 ,K80 <---------------------------------Maybe this? G05 P2 <-----------------------------------And this X-.5962 Y6.6434 Z-.106 Z-.131 F100. X-.5958 Y6.6432 Z-.1391 X-.5947 Y6.6426 Z-.147 X-.5927 Y6.6417 Z-.1548 X-.5901 Y6.6405 Z-.1623 . .

On the Cut Parameters page, what are your settings for Keep Tool Down? I try to remember to set mine to 100% of tool diameter as sometimes Mastercam will randomly set it at 1327% which will yield the same results as you are getting.

Opti rough with Step Up enabled may be what you're looking for. 1" DOC with .25" step-up. Trim the air cuts.

Create Curves All Edges Trim curves to reflect desired surface boundaries Untrim Surfaces Re-Trim Surfaces to new curves

Might be your best bet for success at this point.

only if you don't need multiple stepovers in Z

Verify a roughing operation- Do NOT use Turbo mode Save Verify as STL HSM Rest Rough Select Drive Surfs Select Containment Boundaries Do not select CAD file at this time Set toolpath parameters When you Green Check out of parameters another window will open for you to select STL. Pick your STL and OK Toolpath will begin crunching

Glad we could help!

Probably the most common example of a bad surface is one where surface normal suddenly changes direction. The easiest way to show this would be to draw two lines parallel. Now, create a ruled surface with the chaining direction of the lines going in opposite directions. The resulting surface should be twisted. Use Analyze/ Dynamic to examine the surface and notice how the arrow flips direction near the twist. Typically, you will find this condition on a corner of a surface. In My experience it's usually an area of .005" or less, so you'll have to zoom in really close to see it You can use Analyze/Test Surfaces to find them and change their colors to make them easier to see. Usually you can fix them by untrimming and retrimming the surface.

Not sure of the calculations involved, but using the STL seems to be faster...at least for me. Do you add stock to your tool diameter to account for Stock To Leave? Example: .750 Ball and .025 Stock to leave would yield a .800 Dia roughing tool in Rest Rough .750+(.025*2)=.800 I find that by doing this you'll be less inclined to be surprised when a small tool goes into a rib or other small area that isn't completely roughed out by the previous tool. (No need to do this when using STL)

what are your Verify Tolerances set at? Mine are set at Tool: .008 and STL: .001

Verify all roughing ops. DON'T use the Turbo option in verify. Save verify as STL and pick it as rest material.

Rest Rough with STL is best option in most cases from my experiences.

or, from one file to another, or from one window to another if you run multiple sessions Preselect Geometry, EDIT/COPY or CTRL-C open the new file or make active the window you wish it import to EDIT/PASTE or CTRL-V

Rick, Try leaving EXTRA stock on your Rest Rough. Example: Initial rough leave .010" Rest Rough leave .011" or more

Happened again this morning.