I have the same issue. When I filter the tools it reads that I have 4 of 400 or some such thing and yet the tools don't display. The killer is that at some point later in the day everything is AOK.

I took the Mill_inch.MC8def and Mill_Inch.MC8ops from a co worker's computer and over wrote my own. So far so good.

I'm getting the same error. My tools are coming from here: C:\Users\Public\Documents\shared mcamx8\mill\Tools Is this a big Duh! or am I missing something?

I noticed that when you save a tool to your ops file you can't do it within the tool manager anymore. Every time I use that I have to go and hunt for it. They must have put that in during Easter.

I had this happen sometime back. If memory serves me right, Colin had me change something in the post. Shoulda have written it down, sorry.

This article from MMS might be helpful. I know it's more advertizing than anything but I sometimes find some useful info on them. http://www.mmsonline.com/articles/small-milling-tool-accounts-for-big-productivity-gain-in-machining-forging-dies

I'd be very interested in learning that as well. Any thing to get away from pulling at the cutter with my scale and seeing how much it flexes.

I would also see about contacting that customer about that 1/8 radius on the corner. If sheet metal designers are anything like plastics designers that radius is a probably a totally random number. It doesn't hurt to ask and see if the radius can be increased.

OK. I forgot to mention that I needed a surface file. And then I found out that I cannot write to an FTP site from here. I created the boundaries as you see in the picture; I hope this gives you an idea of how I would approach the cutting. I would finish the main area with a straight 1/2 carbide end mill, preferably one with a solid body as Ron mentioned. I would then rest mill the corners starting with a 3/8 ball, then a 5/16 and lastly the 1/4. Sorry I can't offer more. Maybe someone else can help more than I can. http://i1205.photobucket.com/albums/bb427/fredo_z/diemold_zps864979c4.png

There are many ways to approach a job like this. I would even consider drilling large holes to remove the bulk of material and then go with a bull nose cutter and rip out what remains leaving about .100. That way you can rough out very fast and let your semi roughing (or semi-finishing) tool path bring it in for finishing. . Where I work cavities like this are run over night and weekends. I would not rule out EDM, especially for the 1/8 rad. corners. But electrodes also take time to make and a lot more time to burn. And then there's the cost factor of graphite. On aluminum I would not think twice about milling, on tool steel issues like tool deflection and gouging magnify, not to mention tool wear factor. But I'm just an old toolmaker trying to think something trough.

Thanks, Del. I'll do something with it in the morning, maestro.

Please remind me on how to get to the FTP site. It's been a while for me.

You could finish the ends with the 1/4 ball but it would be sticking out a whole bunch and chatter can be a problem on your finish. Create a boundary for the end areas each and one for the inside area. I would finish wit a 1/2 ball, maybe 3/8 ball using the middle boundary. Finish Surface Leftover the middle area with 1/4 ball with middle area boundary and use Surface Finish: Direction of Contours One Way on the end and also set Flat to 3D using the same amount of step over as your finish vertical wall.. Leave stock for a trial cut and see how your finish looks. From there you can adjust feeds and speeds to get rid of chatter and also adjust your step over amount and get the finish you want. If the above is unclear see if you can put the part on the server and I'll try to generate some toolpaths so you can actually see what I'm talking about.

OK. I did that and MC created a new Mill_Inch Default file. I closed MC and restarted and my retract is there by default. Can't thank you guys enough.

It's not keeping the change I made. Thanks for trying, maybe it's some glitch.

Thanks for your reply. I tried that before. It tells me to edit the Control Definition Manager within the machine Definition Manager. Problem is that the Operations Manager line is not visible so there's nothing to edit. This stuff used to be so easy on V9.

It seems that since X7 I have to check this box for every milling program I make. Is there a way to set MC to default to have "Rapid Retract" on at all times? Maybe it's just me, but I often forget to check that box and myself having to go back when the tool feeds up to Z clearance level.

Your geometry looks like a good candidate for Surface Finish Contour. Is that not an option for you?

I saw the same thing on an Okamoto water grinder. According to the coolant sales guy, bacteria build between the grinder flat surface and the magnetic chuck causing the chuck to swell. (We were having trouble with the chuck not staying flat). Switched to the recommended coolant recommended by Okamoto and problem solved. If you work with a coolant sales person I;d talk to he/she about the problem and they should be able to recommend an appropriate fluid.

Got it. Thanks.

I downloaded X+ but I don't see a way of getting Mastercam to see it. I think some time in the past I had it in Toolbar State. The only way to get the 3-D chain is to run the .dll as a c-hook and I have to do it each time I use it. What am I missing?

I've had my share of problems with that as well. I just don't understand if this is just a Mastercam problem or one of those problems related to computer build. If it is a Mastercam problem you would think they would have fixed it by now.

It is that gummy. Sometimes you're better off using high speed tools on alum. as the edges are sharper. And always have coolant on it, you do not want edge build up.

I've had the same problem and I just select an existing tool and modify it to my needs.

Thanks, Thad.