Try Harvey, they have tip radii down to 0.0025.

It's usually better to start with a solid. It is easy to create a surface from a solid face. More complicated to make a solid "solid" from a hollow surface model. It is also easy to create a curve on a solid edge to make wireframe. Surfaces and solid faces can be useful for different applications.

Even with Vericut it can be a challenge. A local company were the first kids on the block with a Mag 4 high speed cell. Makino turned up with a pallet of spindle cartridges, it took a fair few weeks and a number of spindles to get it dialed in so they could reliably push the button. At 30,000 rpm and 1,000+ ipm FEED rates just a glancing contact can be curtains for the spindle. I think it was about 4 months after they started that one of the supervisors who I worked with in a previous life told me their annualized chip recycling had just gone through seven figures....

Or you could just save it as a parasolid (out of Solidworks).......x_t or .x_b (the best transfer protocol across a range of platforms). This also works for Solidworks assy files, which MC also sometimes has problems with.

Spindle double whammy, you are bleeding at 2x rate, it just isn't good.

Our new Mori has a double bump option, rotating 180 degrees between each bump. This definitely seems to help on 2d offset pickups.

yep, looks suspiciously like code dropping... You can get away with running across electrical cable sometimes, running next to it (parallel) with insufficient space is the big killer . But nothing beats well shielded cable (all cable is not created equal as you inferred), and as much space as possible.

You need to manipulate from within the Operation (Stock or Cutter definition). For most material / tolerance combinations this is sufficient....note I said most....

5 axis machine required to keep the tool normal to the groove floor.

Which base post? Looks like it is set up for longhand drill....?

If you look at psof$ you will notice a control variable (sof), it is initialized as 1 in the misc variables section and at finish it turns off (sof=0). So the test is if sof = 1 you are in psof$ which is where you may or may not want to output. If you don't want to output here you need to save the data and output where you want. I use two buffers to store origin and general text info. and another to output code for probes etc. so one stores "as comment" data and one stores "as code" data Using buffers allows me to exceed the standard character count Do a search for Moving Manual Entries using String Buffers by djstedman to see how to set this up

First step of journey level machining....establish the scapegoat...

I have had good results with a mixture of Moly Dee and Copper Ease even with cut taps... The tools tend to go off pretty quick so you would have to be pretty conservative changing tools. I think I would agree with Ron on this one.

Not much fun....not quite as bad as 324 and 348. Very tough.

You are trying to run an encrypted post processer without both files. Encrypted posts require a .pst file AND a .psb file

The min max z depth is calculated at every operation (and at the end). The tool table is likewise built one operation at a time. Just output your z min value in your tooltable output line.

Just start with Mpmaster.

Harvey

Not quite sure where Mastercam has got to on this. For some time the WCS system was "imperfect" in that it really needed to be on Mastercam zero to function properly in all situations. "Constructed" WCS could be problematic: The origins of some views might be unstable and would need reselecting Things got especially difficult if you introduced multiaxis paths (with 4 or 5 axis) and you lost some functionality, lead lag for instance. As I said I don't know where MC is on addressing the issues (they might all be solved) but I always start on MC zero, especially if I know I might need multiaxis. 4 axis indexing on a constructed WCS is usually OK, but again I usually start on MC zero. Out here in the PNW our main bread and butter is Aerospace and some people argue that using a constructed WCS means you can do everything in airplane space and revved parts come in in the same position. However in 30 yrs of making airplane parts I have NEVER got a chance to get any advantage from this, mainly because Boeing has a habit of rotating suppliers...so I go for the "maintaining functionality" approach and move the part to MC zero.

tseqno : 1 #Output sequence number at toolchanges when omitseq = yes #0=off, 1=seq numbers match toolchange number, 2=seq numbers match tool number General Output Settings at the top of the post.

Check your CAD settings in Config.

Doesn't even come close to multi axis functionality tho. And that's pretty much what we use it for, We can generate simple live profiles on the tubes with a constant z depth. We are starting to pull in more of our small hog out work, so we will probably add the multi axis license here shortly, it doesn't take too much to justify it these days....

FYI 99% of the time there is a better way to do things than Axis Sub, but I do use it a couple of times a year. We do a lot of work on tubes so it can be handy to generate simple live rotation.

Depends how you have set up your system...You can theoretically have your A0 n any plane but MC prefers to be on Mastercam origin (this is especially true with multiaxis), it is less fussy about which way is up or left etc....

As with many aspects of machining its all about method. And it shows when you go and try and machine against the model, models made methodically are often MUCH easier to deal with, and it is often easy to spot the inexperienced. Simple and methodical might sound easy...