I am looking over a part for a quote and I noticed this angled planar surface around a vertical curved surface (see highlighted in preview image of defeatured part). I am at a loss as to how this can be produced on a mill without interfering with the curved surface it is wrapped around. I am hoping someone may know a way this can be made using Fusion and a 5 axis mill.
Attached is a defeatured model of this part with only the problem feature remaining.
Full disclaimer: I've never done something like this.
I think you could theoretically use the bottom of a dovetail cutter to machine the vertical face (tool perpendicular to the vertical face), leaving clearance for the angled surface. You could then use the side of the dovetail cutter to machine the angled face, leaving clearance between the vertical wall and the bottom of the dovetail. In both cases, the outer tip of the dovetail cutter would be directly at the base of the vertical wall. You could probably do the same with something like a low angle spot drill or pointed chamfer mill (the angle would have to be smaller than the lowest angle between those faces). In practice, I'm not sure how great this would come out, since you would be relying on the corner of the dovetail cutter or spot drill to meet exactly at the corner where the two faces intersect.
You should be able to create the toolpath using "multi-axis contour" or "swarf." Unfortunately, in Fusion, you will not be able generate either of those toolpaths using a dovetail mill, spot drill, or even form mill. You would have to generate it with an allowed end mill and then edit the tool to simulate it. I think you will have to play around with modelling surfaces and making different selections to get any of this to work, but it would be an interesting experiment.
The only area you definitely can't do is where it transitions from a flat "ledge" to an angled one. There would have to be a radius there no matter what.
