It turns out the reason for the holes being in the wrong location was due to the post processor output not being correct. The machine was going to the exact position the program told it to go. This was a rare and complex issue to deal with compounded by the difficulty of being able to look at the code and knowing where a problem might be and/or where the machine is going to move.

Thanks for the replies. The toolholder collision was because I used an A axis offset when I set-up the job. I didn't know until now that I can't do that if I'm going to rotate the C axis. So, that part of my problem is corrected. I am having another problem however. I've made parts with holes that are tipped on very shallow angles and the holes are off location by a lot. Some are more than .030 inches off location in one direction. I'm not using cycle 19. Using plane vector instead. I can force the b axis (actually a axis on this machine) positive or negative. The positional errors occur both ways. What's interesting is all 5 axis milling toolpaths perform very accurately. But the 5 axis positioning is incorrect when the A axis is tilted very slightly - less than .1 degrees. I've been told there is only 1 kinematic file which is used for all of the A and C axis moves, which is why it's been so difficult to determine what the problem is. Positioning at larger degrees such as 2,10,45,90, etc. and it goes to the correct position. We have another machine here with the same control. I posted the same toolpaths for that machine and the holes come out fine. Everyone I talk with says they have never heard of this problem. At this point I believe I have a machine problem. I just don't know what to do about it. Neither does the manufacturer at this point.

No solution yet. I'm sending a sample part to the factory in Germany so I'm sure this is going to take awhile. Are you familiar with a 5 axis machine having more than one kinematic table to allow compensation for an offset in the A or B axis?

Hi Niezingerly, Thanks for your reply. I know what you referred to. That isn't my problem unfortunately. Although that did scare the poo outa me too one day! My problem is the machine reads the correct nc and randomly goes to the wrong position. I've ran the same nc in another machine (DMG) and it runs fine. So I believe something is wrong with the machine. No one with Hermle understands this and keeps pointing to the software as the problem.

Hi All. I'm working on a Hermle C400 5 axis mill. Heidenhain i530 control. Ocasionally this machine goes to the wrong position. This isn't a wreck, but for example, yesterday I had a toolholder cut right through a titanium part. This doesn't show up in the software simulation. I've had the nc verified in Veri-cut, no collision. This has been a tough thing to diagnose. I've had multiple conversations with Application engineers to no avail. As far as I can tell the problem has something to do with the kinematic calculations. It only shows up during a 5 axis toolpath. We had the machine tech come to the shop and check the geometry and re-calibrate everything. For the most part this is a very nice machine but it has scrapped parts 3 times now. I've also spent days with the software people (Openmind - Hypermill) thinking that was the source of my problem. It seems like the problem is with the machine. Anyone out there having similar problems? Any insight would be greatly appreciated. Thanks

Ok. Thanks Jay.

I am using stock model for the first time. I read about the issues with it and stayed away from it when I started using X6 since I'm accustomed to using verify & stl's to get from one operation to the next. I'm working on a heavy part (raw matl weighed 1000 lbs.) and I would like to know what the weight of the part is after the first operation because the electric hoist over the machine is only rated for 600 lbs. Is there any way to analyze the stock model so that I can determine the weight? Thanks in advance!

I use YG1 alot because of the price. Performs very well, comparable to Guhring, but cheaper.

Thanks John & Ron. I'll try both suggestions when I get some time. Your help is much appreciated!

Thanks Ron & John. I'll check out both once I get some time. I appreciate your help!

John, Can you explain the dynamic wcs that you mentioned earlier? I tried mastercam help & couldn't figure out how to do it. I import models all the time & always have to 3D translate them to align them with the WCS so if there is an easier way I would like to know how to do it. Thanks in advance!

+1 THe Haas alarm "H and T numbers not matching" has saved my a$$ a dozen times!!!

thanks peon for the heads-up! I use custom tools all of the time and am just starting to use X6 so I'll keep an eye out for it.

in X5 MU1 it works every time if you close the file first and then try the projection immediately after opening the file.

It was the config file. When I deleted the old config file and started with a new one all of the file mapping issues went away. Thanks to all!

Hi Chris. You used to help me alot when I worked at Billet Industries in York. Now I'm in Denver doing alot of aerospace work. I used the web download to update to x6. Can I still do a repair install as you described? Thanks in advance. Jeff Cooke

Thanks for the response. It's not the filename that is the problem. When I open the configuration settings and select the default machine definitions the folder that is listed is the mcamx5/cnc machines folder. When I attempt to change the folder to the mcamx6/cnc machines folder that is when i get the error saying bad filename. My reseller said that it must be a bad install so I uninstalled the software several times now. Same results every time. Frustrating!

Hi everyone. I'm attempting to update from x5 MU1 to x6. I downloaded John's pdf file and did the folder update as described. When I open x6 my config, keymap, & toolbars files are fine, but the machine & control definitions are still set to x5. When I try to select the folder for the default machine definition I get an error saying invalid file name. The machine & control definitions were updated fine, I just can't select them in the x6 configuration. I'm using Windows 7 & am not computer savvy by any means. If anyone can help me figure this out I would appreciate it greatly. Thanks in advance!

I've wondered about this since the ability to change speed & feed first showed up. It's available in several toolpaths mentioned above & others, but not contour. Does anyone know if that will be added in X6? It sure would be nice!

I have had similar problems as reported above. My os is Windows 7 & Mastercam crashes alot for me when I copy toolpaths and then change settings in the copied toolpath, particularly depth cuts. Does anyone know if this is fixed in X6? Thanks. My sig. is wrong, I'm using X5 MU1.

Thanks guys. I didn't realize that the filter would apply with linear cuts as well as arcs. I appreciate the help!

Hi guys. I've used this forum for awhile at another company, but had to change my user name. Glad to be back! There's alot of good stuff here. I use these toolpaths like sled, and they work very well for roughing. Does anyone know why the code is written with so many small line moves even though the tool might be moving in a straight line? Thanks, Jeff