topic Re: FUSION GOUGHING - Mold Cavities in Fusion Manufacture Forum

FUSION GOUGHING - Mold Cavities

anewenergy — Wed, 30 Sep 2015 19:50:48 GMT

OK, I'm running an old Mori Seiki MVJR with a FanucM10 controller. When I backplot, we do not seeing anything out of the ordinary with the code. Never got this gouging when I ran Cimatron. Here is my Fusion CAM file: http://a360.co/1YP4pUO

Below are images. Could be the machine. Any post improvements, or recommendations on tweeks?

Fusion on a brand new iMac work station. Sept 2015.

Re: FUSION GOUGHING - Mold Cavities

HughesTooling — Wed, 30 Sep 2015 21:54:43 GMT

Are you using one of the generic posts or have you got a custom one. If it's a custom post can you attach it to a post.

Thanks

Re: FUSION GOUGHING - Mold Cavities

anewenergy — Wed, 30 Sep 2015 22:24:48 GMT

Hi Mark,

Thanks for circling back. It is a generic FANUC post with one custom "No Sequencing" turned off. In the past when I ran big files I had the controller stop feeding data, while responding with "too many digits." We found that Show Sequence to Off in the Windows version of 360. I am now running a iMAC. Below is where we were, and where we are at with the new MAC generic version.

Here is the new MAC settings

Thanks again for your help

Pat

Re: FUSION GOUGHING - Mold Cavities

HughesTooling — Thu, 01 Oct 2015 13:27:58 GMT

I had a look through your file and there doesn't seem like you should have a problem. In the area you have the gouges the toolpath is very simple, just straight line moves there aren't any arc moves in the area that might cause a problem. Are you 100% sure you've not changed the file from when you posted and cut the part because I would not expect gouges like you have from climb milling. Is there any chance you had cut direction set to both ways. Have you got a backup of the actual g code you used.

I have a couple of ideas you could try in a situation like this.

1. Set a minimum cutting radius so you're not going straight into a sharp corner.

2. Use Feed Optimization to slow the feed in corners.

Getting minimum radius and Feed Optimization to work together can be a challenge, try these settings. Also you might want to have one operation to do just the pocket as it takes longer to calculate with these settings.

Here's the new toolpath.

Re: FUSION GOUGHING - Mold Cavities

hjoy — Thu, 01 Oct 2015 18:12:53 GMT

Looks like classic tool deflection in the roughing stage or machine inaccuracy at the corner.

Regards,

Harri

Re: FUSION GOUGHING - Mold Cavities

jeff.walters — Thu, 01 Oct 2015 18:23:10 GMT

Looking at the screen shot where it’s in the corners and not on every level, and the tool path it looks like tool walk where it’s burring its self in the corners. I would recommend using 3D adaptive. The constant tool load is meant to avoid just this situation. Even if you don’t have a high speed spindle it will do wonders for your roughing. You will find you can still take deeper cuts at a faster feedrate and most likely take some time off the 32hr cycle time.

Re: FUSION GOUGHING - Mold Cavities

anewenergy — Thu, 01 Oct 2015 19:07:51 GMT

Here is another cavity that just gouged. Ouch again. Ran the settings suggested. Here is the file shared: http://a360.co/1KXvgUv

Here is the cam path.

Here are the settings per your recomendations.

Re: FUSION GOUGHING - Mold Cavities

HughesTooling — Thu, 01 Oct 2015 19:51:02 GMT

Well that's a completely different situation. There are so many things wrong with what you're doing. You have a long series cutter in a small diameter holder and you're cutting in both directions. When the cutter is cutting in the conventional direction it is going to pull into the job and on that angled face when it starts to pull the load will keep increasing and the cutter will just keep deflecting more and more.

You need to keep all the overhangs as short as possible use a carbide cutter in as big a holder as you can and try to avoid conversational cutting direction. That setup explains the gouges you had in you first example as well.

Re: FUSION GOUGHING - Mold Cavities

anewenergy — Thu, 01 Oct 2015 20:03:21 GMT

Mark,

I had been using both of these in this format before for quite a few months. I will try a conventional spiral to keep in a conventional milling format. Lets give it a try.

Pat

Re: FUSION GOUGHING - Mold Cavities

Anonymous — Thu, 01 Oct 2015 22:11:57 GMT

@anewenergy, Avoid conventional milling. Use climb milling. That's what Mark is trying to tell you. I agree with others, these are tool deflection gouges. Can happen with bad roughing strategies. It can happen to improper tool selection (too long). It can happen by not leaving enough stock for the finishing operation. Roughing is roughing for just that reason. I suspect you are having dificulty since starting using Fusion is simply because the strategies are different, maybe default stock to leave is less, entry different, etc.

If I get a chance later, I can take a look at the file and offer some specific advice. I hope to not offend you. I know this because I've done it myself. We all have at one time or another.

Re: FUSION GOUGHING - Mold Cavities

anewenergy — Thu, 01 Oct 2015 22:16:31 GMT

Thanks Paul,

Its all climb. Been a long day. I mispoke. I have been using these exact cutters and speeds and feeds for years with Fusion. It is all going.

Re: FUSION GOUGHING - Mold Cavities

HughesTooling — Thu, 01 Oct 2015 22:27:14 GMT

In your last example this is probably the cut that's caused all the problems. If this first cut on the core had been in the opposit direction you might have got away with it, just bad luck and perhaps just one of those weeks/jobs when all the luck is bad.