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MatthewECornelius
439 Views, 9 Replies

5 Axis Ball Endmill Strategy - Need Help!

Hello Forum!

 

Well after my last embarrassing topic I posted and was solved easily, I am back to the task at hand. I am looking to develop a ball endmill strategy to machine the areas in RED on the part I have uploaded. I have tried to make a few 5 axis paths and I just don't know what I don't know. I have the machine I want to use and the kinematics all set and I want the tool to curve in and out of the part to cut the slots in red in the bore. I need to do this with multiple depth cuts, and include one spring pass. We currently do these on a manual with the tool tilted at a fixed angle while using a tilting rotary table. I prefer to start at the bottom and sweep up as this ensures the tool is not pushing into the material.

 

Again if this feature could be machined in a way where the tool starts at the bottom and goes to the top all while automatically tilting the part to allow clearance and do this with the option of having multiple depths of cut, this would be great.

 

Thanks,

 

Matt

on my end the whole part is essentially red....


You can use a 1/4 ballnose with tool orientation and Contour or trace to do what you want. Similar to how a Bridgeport would do it, or 3D parallel with a smaller tool. 


Please click "Accept Solution" if what I wrote solved your issue!

MatthewECornelius_0-1699379533818.png

I have added a screenshot of 1 of the 3 features.

Hi

I wouldn't do this with 5 axis motion(you can but its not necessary)

You can use FLOW with tool orientation(15° tilt) in 3 axis mode.

I have made 3 toolpaths with reducing stock to leave for the multiple depths of cut, then added them to a circular pattern to machine the other two grooves.

 

This isn't quite what you were asking for but is pretty close.

 

 

See what you think, if its not suitable then we can try some other ideas, but this is by far the easiest

I figured, from context

You can use a 1/4 ballnose with tool orientation and Contour or trace to do what you want. Similar to how a Bridgeport would do it, or 3D parallel with a smaller tool. 



Please click "Accept Solution" if what I wrote solved your issue!

I grabbed a junk part and did a quick video of what I want. I would like the tool tip perpendicular to the tangent point of the bore. I wish you could just draw a line in 3D, then add multiple depths, and then add a line or point for tool control. It's literally a trace path in a bore that needs tilting for clearance.

Why do you want to rotate the tool around like that though?(Other than for cool 5 axis motion?)

You end up cutting on the Tip which is less than optimal as the surface speed is approaching zero and the flute clearance is very small.

 

Cutting at a fixed tilt will give the best results in this case.

You're right, I do need to keep it at a fixed tilt. I found this article on my exact issue, I think I am going to give it a try. I will keep you posted.

 

https://www.manandmachine.co.uk/fusion-360-cam-cutting-axial-grooves-on-a-turned-part/

yeah, that's my trace with tool orientation advice but with extra steps of having to draw your own tool path!

Please click "Accept Solution" if what I wrote solved your issue!

Thank you all for your suggestions as they helped me learn quite a bit about how to control the tool for features such as the one I have described. I found that the PROJECT tool path has the features in it I was looking for. I will be able to draw a sketch to control where I want it to cut, but most importantly I can set this up using the parameters page and turn this into a macro program so to speak. Here is a comparison between the FLOW tool path and the PROJECT tool path. PROJECT offers more control in this instance than TRACE and less erratic moves than FLOW.

 

Flow:

MatthewECornelius_0-1699450056670.png

 

Project:

MatthewECornelius_1-1699450081402.png

 

I will accept ALL inputs as solving my machining example as they are all great ways of thinking outside the box.

 

Thanks again!