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ian1196
447 Views, 3 Replies

Machining fillets at different angles with ball mills

I made a test box with lots of fillets. See attachment. I would like to cut the part with only two 1/4" end mills. The first end mill being flat would rough out the box. All the vertical and horizontal entities would be complete. The next tool would be a ball mill. The inside bottom fillet would be no problem(pencil). How would one cut the outer rim only using the two tools mentioned? I made this box as a generic design as it contains similar issues I would encounter. Please help.

Thanks.

s.noke71
in reply to: ian1196

Hi Ian,

What material are you using? you are 5xd with the 1/4" are you punching a hole in the middle?

Ripping it out with a 10mm and then rest machine the corner could also work for you.

 

Steve

s.noke71
in reply to: ian1196

Ian i would also run an adaptive path around with a .05 fine stepdown this will form most of the rad leaving you to use  parallel to finish the rads.

ian1196
in reply to: s.noke71

In this example, the material would be Delrin of some other easy to machine plastic. Before posting, my thought was to pocket away the center, using the same flat mill, do a parallel at about 0.008" step over. Make a copy of the parallel but change the rotation to 90 degrees. Switch to ball mill and pencil out the bottom corners. That would work but there is a lot of air cutting. I was hoping for a more elegant solution. Thanks.