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designingberlin
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how to 2D chamfer a web structure without overloading the chamfer tool

Hi all,

here is a question. I've a lightweight shell / web structure for  CNC milling. The machined pockets will have some corner radius that I don't want to model (performance issues in fusion with seberal hundred fillets).

I still want to add a 2D chamfer to the machined pockets. This may results in a bad situation for the chemfer tool:fusion3.jpg

 

The chamfer tool tip will machine into the corner. Not good.

 

Is there a clever way to machine and chamfer such a shell / web structure without modeling all the corners?

 

I can use a large diameter chamfer tool and adjust the tool tip offset for the chamfering operation to match the actual fillet radius. That works, but the chamfer tool will run into unwanted high chiploads in the tight corners and for shallow pockets the chamfer tool tip will penetrate the pocket bottom face ...

 

For now I do model all fillets, but it slows down fusion a lot and minor design changes require reselection of corners more often that I want.

 

Thanks for your suggestions!

 

Happy CAMing.

Stefan