1mm ball end tool path error

[mark]

I am newbie trying to machine a mould from aluminium plate on my Tormach 770.

I have successfully machined most of the mould in test passes including the square and circular pockets. 

My trouble is in programming the logo pocket with a 1mm ball end mill. I am trying to use a 2D pocket path to machine the pocket which is 0.5mm deep. The pocket design was created from a dxf file and has narrow parts, but nothing the 1mm should not fit into, especially since it's only 0.5mm deep.

Every time I try to create the path Fusion gives the error:

Warning: Cusps cannot be avoided with ball tool.

Error: (ensureCutRadius > 0) and (ensureCutRadius <= cutterRadius)

Here is a screen shot of the mould in Fusion and a photo of the partly completed mould.

How can I get Fusion to create a machine path for the logo

[Steinwerks]

The error should be telling you that the minimum radius has to be greater than zero and less than half the diameter of the tool.

If this doesn't help, attaching the file as a .F3D would be very helpful in troubleshooting the issue.

[mark]

Thanks for the reply.

I'm trying to work out which radius Fusion is referring to here.

Is it the radius of linework in the XY plane or, the radius at the bottom corner of the pocket?

- the XY plane is all smooth curves (from the DXF file imported).

- the bottom edge of the pocket has a zero radius.

My cutter radius is 0.5mm, so I tried modelling a bottom edge radius of 0.25mm (0<0.25<0.5) but it gave the same error.

I have attached the file here as well. Hope it makes sense.

[mark · Accepted solution]

So I tried changing the toolpath type from a 2D pocket to a 3D pocket and success! The toolpath was created for the ball end mill and I managed to get a perfect cut on the CNC first time.

Not sure why a 2D pocket function wouldn't work but doesn't matter I'll just use 3D for this from now on.

[mark · Accepted solution]

I'm going to add another solve for this post that allows the 2D pocket to work with the ball end mill.

I discovered through a lot of forum-trawling that when you edit the tool path, under the passes tab there is an option "allow stepover cusps". This box needs to be checked to make the tool path work.

[jmj4331]

Mark,

I saw this post......4 years old.......and it solved my issue that I have been arguing with and  "Googling" for months!

THANK YOU!!!

[daliso_bandaRXXWC · Accepted solution]

Had similar issue, switching to 3D pocket also solved it for me, thanks for sharing!