topic Re: Error: (ensureCutRadius > 0) and (ensureCutRadius <= cutterRadius) in Fusion Manufacture Forum

Error: (ensureCutRadius > 0) and (ensureCutRadius <= cutterRadius)

etfrench — Wed, 13 Apr 2016 23:49:51 GMT

How can I resolve this error: Error: (ensureCutRadius > 0) and (ensureCutRadius <= cutterRadius)

The machining operation is a 2d pocket where the red arrow is located. The toolbit is a .25in ball end mill. For scale, the round pocket above the arrow is .5in in diameter. I've tried using values from .001 to .124 for the Minimum Cutting Radius with no success. A similar pocket on the reverse side does not have the same problem.

Re: Error: (ensureCutRadius > 0) and (ensureCutRadius <= cutterRadius)

scottmoyse — Thu, 14 Apr 2016 08:39:48 GMT

Why are you trying to use a tool that's only just half the size of the pocket, and a ball mill at that? It seems odd. You might get it with a 3D Pocket, because it would lift the tool to suit the model where possible.

Re: Error: (ensureCutRadius > 0) and (ensureCutRadius <= cutterRadius)

etfrench — Thu, 14 Apr 2016 17:28:02 GMT

The larger the ball mill, the smaller the cusps. It's not necessary to model the fillet in this case. I'm more interested in finding out what the error means and how to correct it. Changing the operation type is a valid workaround, but doesn't answer the question.

Re: Error: (ensureCutRadius > 0) and (ensureCutRadius <= cutterRadius)

scottmoyse — Thu, 14 Apr 2016 19:18:26 GMT

The error means it doesn't have enough space to do what it needs to. You said you have got it to work with a similar pocket, but that must be a larger diameter pocket.

Re: Error: (ensureCutRadius > 0) and (ensureCutRadius <= cutterRadius)

etfrench — Thu, 14 Apr 2016 21:29:09 GMT

Sorry, but I don't think that's the right interpretation. The pocket is larger than the tool bit in both X and Y axes. In fact, changing to a .125 ball end doesn't fix the error.

Re: Error: (ensureCutRadius > 0) and (ensureCutRadius <= cutterRadius)

scottmoyse — Thu, 14 Apr 2016 22:57:26 GMT

Can you attach the model with one example where its working and one where it's not. I've replicated your error at my end, and it works with a bigger pocket.

Re: Error: (ensureCutRadius > 0) and (ensureCutRadius <= cutterRadius)

etfrench — Fri, 15 Apr 2016 00:08:43 GMT

I misspoke earlier when I said the same operation worked on the bottom. The working operation was 2d adaptive instead of 2d pocket.

The model has changed slightly from the original, but the error still exists.

Re: Error: (ensureCutRadius > 0) and (ensureCutRadius <= cutterRadius)

jeff.walters — Mon, 18 Apr 2016 14:55:03 GMT

There are a couple of issues with the way you have things selected. The first is that you selected a face instead of the edge. This is one of the issues with fusion right now that the developers are working on. You should be selecting edges.

The second issue is that the face you selected is outside the stock you have defined so even if you hade selected the boundary correctly you mostly likely wouldn’t have gotten a tool path.

Re: Error: (ensureCutRadius > 0) and (ensureCutRadius <= cutterRadius)

etfrench — Tue, 19 Apr 2016 21:23:01 GMT

I can get a toolpath like that if I use a flat end mill. When I change the tool to a ball end I still get the cutterRadius error. I don't understand the error message or how to correct the toolpath to eliminate the error while using a ball end mill.

Re: Error: (ensureCutRadius > 0) and (ensureCutRadius <= cutterRadius)

scottmoyse — Tue, 19 Apr 2016 21:58:48 GMT

@jeff.walters wrote:

The first is that you selected a face instead of the edge. This is one of the issues with fusion right now that the developers are working on. You should be selecting edges.

The second issue is that the face you selected is outside the stock you have defined so even if you hade selected the boundary correctly you mostly likely wouldn’t have gotten a tool path.

@jeff.walters are you saying that you can't even select a face in the bottom of a pocket for a 2D pocketing operation? Even though it works most of the time, and this is the first time I've encountered not being able to do that?

Also the Stock isn't a factor in this error. I replicated it with a really simple 3-axis dataset. Extruded rectangle with the pocket & tool diameters shared in the OP., then a default setup.

Re: Error: (ensureCutRadius > 0) and (ensureCutRadius <= cutterRadius)

HughesTooling — Tue, 19 Apr 2016 22:41:51 GMT

etfrench wrote:

I can get a toolpath like that if I use a flat end mill. When I change the tool to a ball end I still get the cutterRadius error. I don't understand the error message or how to correct the toolpath to eliminate the error while using a ball end mill.

You need to enable Allow Stepover Cusps

Then it generates.

Mark

Re: Error: (ensureCutRadius > 0) and (ensureCutRadius <= cutterRadius)

scottmoyse — Tue, 19 Apr 2016 22:43:26 GMT

I tried that with my example the other day and it didn't work. I'll take another look later if I can.

Re: Error: (ensureCutRadius > 0) and (ensureCutRadius <= cutterRadius)

HughesTooling — Tue, 19 Apr 2016 22:46:30 GMT

I've attached the file, I cleared all toolpaths to reduce size so you'll have to regen.

Mark

Re: Error: (ensureCutRadius > 0) and (ensureCutRadius <= cutterRadius)

BjoernJohnsson — Wed, 20 Oct 2021 07:02:23 GMT

From a brief investigation, I think one issue is that you have two selection with different orientations in the same 2D operation. I would suggest splitting it into two different operations and set the tool orientation aligned with the selected surface in the second of the operation.

I've attached a new version of your example file where I do this.

Re: Error: (ensureCutRadius > 0) and (ensureCutRadius <= cutterRadius)

etfrench — Wed, 20 Oct 2021 07:23:17 GMT

The part has been working on my delta 3d printer for 5 years now 😄

Re: Error: (ensureCutRadius > 0) and (ensureCutRadius <= cutterRadius)

BjoernJohnsson — Wed, 20 Oct 2021 07:31:23 GMT

I missed the date on the original post, just saw that the thread got a lot of views recently.

Re: Error: (ensureCutRadius > 0) and (ensureCutRadius <= cutterRadius)

etfrench — Wed, 20 Oct 2021 07:39:36 GMT

It never hurts to add more info.

Re: Error: (ensureCutRadius > 0) and (ensureCutRadius <= cutterRadius)

vbXAKEE — Sat, 05 Apr 2025 19:10:27 GMT

allow steopver cusps fixed it for me