Need help on 2d side cut. Boss Hates cutting air!!!!

[Anonymous]

Guys can anyone tell me  how to make this cut with out cutting all the air. I've tried everything I know and havent figured any way to do this. My boss pulls his hair out everytime he watches this tool path. Honestly i cant blame him we make money by cutting chips not air. Please see the below picture.

Notice all the time lost cutting airis there a way to make it only cut to the right of the red line ??

I need the tool path to expand with the geomtry of the part not just follow the 2d curve that Feature creates any help would be greatly appreciated!

[bhorstTGM48]

Can you please attach your .fm file?

[Anonymous]

Here you go 

[AJHanson · Accepted solution]

Check this out and see if this helps. I created a surface which I roughed out then used your side as a finish. If this answers your question please except a solution.

[Anonymous]

that is what i was looking for. Is there as way to make it lead in from just a touch futher out so its not plunging into the material. ? 

[AJHanson]

Yes, you'll need to go to the srf mill properties and under the leads tap change to loop using on all plunges/retracts

[bhorstTGM48]

@AJHanson Can you please summarize how you created that surface?

[AJHanson]

I created the surface by using create surface from feature, I used the side feature to create the surface. I have found that if i extend the surface out it seems to cut better, however to do this was very cumbersome, with out plunging on the material but leads in and out work too

[bhorstTGM48]

After you created it did you have to trim it to the radius?
https://www.screencast.com/t/s96bU8YlCJ

[AJHanson]

Yes, but before i did I extended it along with the curve I created using intersection function then I did my trim. As shown in image.

[Anonymous]

This does stop the air cutting. However after some checking the no air pass cut actually takes longer to run. So yes it is a solution however its not any faster cut wise.

[AJHanson]

You can change your depth of cut by changing you scallop height. changed mine to .020 with a step over of .050  ..