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Tbaker25
1155 Views, 10 Replies

Weird rest machining behavior on 1/32 ball mill

I'm machining a mold. I have some complex forms which I'm roughing out with adaptive clearing, first 1 .5" EM, then a .25, then .125, then .03125. I'm doing rest machining for the subsequent passes. It works fine for the larger tools. But when I get down to the 1/32, it will create tool paths for all surfaces, regardless of the value in Ignore Cusps. My plan was to adaptive clearing to get down to 2 thou of stock, then do a finishing pass for a very smooth surface. But adaptive clearing wants to have that tiny bit touch every surface in my bounding area. I just want it to hit the small corners which the previous tools didn't get to.

I've tried stock from previous operations, ignore cusps from 0.005 to 0.1. Same results.

 

Is there a different way I should be approaching this problem? This tool is a mold cutting taper neck extended reach bit, 0.5" long. So the cut needs to be carefully controlled, the EM maker recoomends only 10% DOC and 10% WOC. No other path I've found offers me the control to make sure the bit never gets loaded more than that.