3D Adaptive Clearing tool crash on third pass

[Anonymous]

3D Adaptive Clearing has a tool crash on the third pass when plunging down into the material after a horizontal rapid into position to clear the final section of the layer. Changing feed rates, plunge rates, allowing only radial rapids (with a very slow axial feed rate) make no difference. I have never seen this before, but this is my first time with the latest update. I have attached a PDF that may help clarify what is going on. Changing maximum depths only changes when this occurs, unless I set the depth so only one pass is needed, but my machine will never handle that (deep cuts often result in tool pull-out because the machine is underpowered).

It is strange that the second pass is ok, but the tool rapids radially further on the third pass, resulting in the crash on the plunge. One would think the algorithm would produce an identical tool path as it is just another layer. I am guessing the bosses at the other end confuse the issue, shifting each tool path enough to produce this problem. I would call this a bug, but I am retired from software development.

[seth.madore]

Any chance you could share the file? I can't quite tell from the photo where the crash is occurring.

Do you mean that it happens in real life but not in the simulation?

File > Export > Save to local folder. Return to thread and attach the .f3d file in your reply

[M&GToolWorks]

Seth, if he cannot share I will look and see if I have a file I can. 

Recently I have had several parts that the tool plunges into stock with 3d Adaptive. I have not found a way to fix it other than to reduce my plunging speeds. 

Sometimes it is shown in Simulation as a collision with stock, sometimes it is not. 

I have never had this problem before, and would be curious to see a fix, whether that is from the software side or if I inadvertently changed a setting. 

[johnswetz1982]

Without seeing your file to know for sure, try changing the lead in and lead out sizes to be bigger. The 3D work that I've done occasionally has rapid collisions with stock and that always seems to work for me to clear the collisions. 

[Anonymous]

It happens in the simulation, sorry I wasn't clear about that. The last picture shows the tool, in "collision" red, as it has impacted the material during the plunge in the third pass. The previous pictures are the same simulation step, but in a previous layer of machining in the simulation, and you can see the tool clears the material. I have attached an f3d file that I exported. Is this the correct file type?

[daniel_lyall · Accepted solution]

@Anonymous  Fusion does not like a , in a files name you have to rename it to get it to open.

Changing the tolerances to .001 seems to fix it for me.

[seth.madore]

Many things will fix this. Here are two:

1) Tighten up your tolerance. Setting it to .0005" makes the collision go away, at the expense of longer calculation time.

2) Increase your leads to .05". This is the quicker, but less accurate method.

What is your machine? That's an awfully light cut, that endmill is going to wear out at the tips 🙂

[Anonymous]

Changing the tolerance to 0.001" fixed it! Thanks to the two suggestions to change tolerance. I had just left the default.

The machine is a Tormach 770 with E8 collets. I have found that more aggressive cutting (greater depth) has led to tool pull-out, resulting in self-ramping until damage. I am just a hobbyist and inventor, so my nerves would rather I do it this way. I don't do a lot of machining.

[daniel_lyall]

What Tool holders are you using?  you mean an R8 tapper 

[Anonymous]

Sorry, my brain was elsewhere. I'm using ER20 collets in Tormach holders. I torque the nuts, clean the threads, and I still get tool pull-out with aggressive cuts. I'll probably increase the cut to 0.150" for the machining. The machine just doesn't have very much torque or HP. But, I do have my own CNC machine in my garage to do with as I please! I'm also learning that 18 months with Fusion 360 is still not enough to know all the ins-and-outs of the software, i.e. with today's computers, why is the Tolerance defaulted to 0.004"? In my naivety, I figured there must be a good reason, but that was clearly not tight enough for my needs.

[daniel_lyall]

Have you had a look here https://www.youtube.com/channel/UCe0IyK4ntgdPTTjsxjvyHPg 

[M&GToolWorks]

"This channel does not exist" 

is what I get when I click on the link

[daniel_lyall]

https://www.youtube.com/user/saunixcomp/videos

[Anonymous]

This link, ".....Videos" is a top level YouYube page with a bazillion videos. I'm not sure what I am supposed to look for.

[daniel_lyall]

There are a lot of tormach videos in there that will help with the feed and speeds look for those ones.