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Best way to machine this 3d part ?
hello, maybe some of you experienced CAM wizards can give me some pointers here.
Firts a couple of points to note and disclaimers:
- i have no formal education in CAD or CAM, all self taught
- my 'CNC' is actually an engraving machine from the 80's which i converted to work as a 3-axis mill with Mach3
- my spindle is super weak, it only has 75W motor and worse of all it's belt driven, so it has very very low torque
- due to the low torque i can only step down 0.5 to 1mm at a time (depending on material hardness)
- the machines frame is extremely sturdy but tiny fast moves are problematic
- motors are not the fastest: max 3000 mm/min but most of the time i'm running somewhere betweenm1000 and 2500 mm/min
- i have no speed control on the spindle over GCODE, only a manual on/off switch with a poti for rotation speed (max spindle speed ca 12000 rpm)
- i mainly work with wood and other natural materials
- despite the lack of formal education in CAD and CAM i'm sucessfully and happily chipping away for 3 years now and manage to execute most of my projects without too many problems
- my experienc in CAD/CAM is mainnly based on Rhino and Rhinocam but i really want to switch over to Fusion completely
that being said i'm currently working on a bridge for an electric solid body guitar which will be cut out of Gabon ebony which is extremely hard to cut on this machine (meaning a max stepdown of 0.25 or 0.5mm)
The problems i'm facing at the moment is to generate a good machining strategy for this part and i'm running into 'Rapid Stock collisions' i can't seem to get rid of. Due to the weakness of my spindle this is a huge problem, spindle will stop rotating, belt will slip and eventually break and i'm risking to bend the mechanical parts of the machine and so on.
When doing roughing operations like this i usually clear away the stock around the part with a contour operation to avoid collisions like this but here i can't seem to avoid this (problematic areas in red are where the tool will enter the material at way more than the 0.5/1mm stepdown):
With my previous Rhino workflow I've developed ways to avoid this and get around machining smoothly but with Fusion i'm still struggling to find my ways. I've played around with different strtegies for a coupl of hours but can't seem to find a smooth workflow here ...
So maybe some of you have some ideas and tips ? I attached the file as an f3d, hope the cam operations come through as well.
PS: i'm not so concerned about the detailing, slots and holes and finishing, my main problem here is to efficiently clear away the rough material without breaking my cnc machine. The bottom of the part also is not so much of a problem, i can get away with a simple pocket and finishing operation.
GENERAL DISCLAIMER: if there isn't a file attached to my posts then there is a reason for it. wherever i can i will attach a file for troubleshooting.If no file is attached i will always try to explain as clearly as possible with illustrative screenshots. when i have an issue that can only be helped by attaching a file which i cannot share publicly i won't ask about it here.
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What you are doing is really a pocket so you need to set the adaptive clearing more like a pocket.
Here's the sim.
I've attached the file, I deleted the second drill op as it had some odd heights set.
Mark
Mark Hughes
Owner, Hughes Tooling
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Just noticed the 2d contour is also plunging into the stock, you can use ramp to stop the plunge. You can actually cut to the full dept with a ramp with these settings, turn off multiple depths on the passes tab.
Mark
Edit you might want to reduce the Ramp Clearance Height to 0.25.
Updated file attached.
Mark Hughes
Owner, Hughes Tooling
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wow, that's much better indeed ... i'm not sure i understand what made the difference here .. you say 'set the adaptive clearing more like a pocket.' how did you do this, is it the 'rest machining' option that makes the difference ?
The odd drill heights of the second drill operation are intentional and a result of my odd clamping technique documented here: https://forums.autodesk.com/t5/post-your-tips-and-tutorials/cam-the-toothpick-skewer-trick-or-the-po...
i knew about the ramping but didn't set it up here since i'm not ready to machine and just wanted to have it in the simulation .. i was concentrating on the adpative operation and would have set up feeds(speeds and ramping when i'm ready to cut.
GENERAL DISCLAIMER: if there isn't a file attached to my posts then there is a reason for it. wherever i can i will attach a file for troubleshooting.If no file is attached i will always try to explain as clearly as possible with illustrative screenshots. when i have an issue that can only be helped by attaching a file which i cannot share publicly i won't ask about it here.
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To make adaptive work in a pocket select a boundary profile and I set the tool containment to Tool Outside. You don't need the stock contours select like I have here if rest is selected.
Mark
Mark Hughes
Owner, Hughes Tooling
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