4th axis Rotary Engraving on Tapered Surface issues

[ahippemail]

Im running into some real issues with trying to engrave a tapered cylinder using my 4th axis. The challenges are as follows. 

1 - Trace doesnt support wrapped toolpaths

2- 2d Contour doesnt seem to support the tapered surface and wants to plunge straight in

3- Project will follow the surface correctly but doesnt support wrapped toolpaths. For the hashes its fine as I can pattern those but when it comes to engraving the numbers or anything else, I would have to have a new setup for every single number since it doesnt support wrapping to allow me to index the 4th. 

Ive downloaded the machining extensions to try out but not seeing anything there that provides much help either so I know I must be missing something. 

At the highest level the toolpaths that will follow the contour to engrave, do not support wrapping and would require a new setup for every number to get it to index. The toolpaths that support wrapping do not seem to support the tapered surface for using the rotary and will just plunge straight in for a parallel to the rotary axis toolpath

I would like to be able to create all the numbers/hashes and then use a single toolpath to select those contours and engrave them while indexing the 4th but not having much luck. Any thoughts?

[seth.madore]

Could you share your Fusion file, or an image of the part and the text? That would help us get a better sense of geometry and possible solutions.

This is on a 4-axis only machine, right?

[ahippemail]

There is an image attached to the initial post. I will upload a fusion export shortly

[seth.madore]

You're on the right track with Project. However, you want to use single line fonts, not the fonts that are intended for Engrave operations:

With "Project", you'll also want to specify a negative Axial Offset to get the tool to cut into the material

 

[ahippemail]

Project doesnt solve the problem since i would have to create a new setup for every letter/ number being indexed to keep the tool tip on center. There should be a toolpath or method that allows you to wrap the toolpath to select all the text contours on the taper and have the 4th index vs just moving in Y. 

You can do this on a cylindrical sirface using a wraped 2d contour but NOT when there is a taper on radius that changes in that toolpath. 

[seth.madore]

You don't need a new setup for each character, just use Tool Orientation and program each character in its own toolpath:

I recognize that this is less than optimal. For the moment, it's the "best we've got", and we now that it's sub-optimal.

I know we're working on some nice multi-axis toolpath options that might solve this, but they are a ways out..

 

[seth.madore]

The other "single toolpath" option, and one that will likely be a better solution is to define a small ball endmill and use "Project". Set "Tool Axis" mode to "To Curve" and select the axis as shown:

 

Result:

Do note; it really should be single stroke text, not embossed TrueType fonts.

You can use this same method for the hash marks 

 

[ahippemail]

Thanks for all the help. While I agree this is not ideal, it does put me in a better position that I was before. Seems like if 2d contour works on cylindrical surfaces that 3d contour should work on this but unfortunately, it doesnt. 

[seth.madore]

3D Contour doesn't really have the capacity of doing "end work" with tools, that's the problem

[dkG4NJT]

Hello! I faced the same problem. Tell me how to wrap text around a taper surface? And perform it on a machine with 5 axes HAAS VF2 + TRT 160, I can position the part so that the tool axis is perpendicular to the surface.

[seth.madore]

@dkG4NJT Would you be able to share your Fusion file here?
File > Export > Save to local folder, return to thread and attach the .f3d/.f3z file in your reply.

[dkG4NJT]

test part