Error: Selected face may not be safe for cutting at current tool orientation!

[mrwhitbread]

Hello everyone, I'm experiencing a very odd issue that cropped up today. Backstory, I've already successfully posted process for and milled these parts with no errors. I have 2 variations of the same part. Fusion was open for a few days, crashed, and reopened with a "here's whats's new update" banner. I then made a minor dimensional change on the original models, updated the linked models in these two setups, and regenerated tool paths. The one setup regenerated the all tool paths just fine. The other setup refuses to regenerate two particular tool paths only.

I've tried deleting the operations and remaking, I've tried redefining the setup origin, copy/pasting the 2 operations from the setup they worked in to the other setup, tried turning tool orientation on/off, and nothing seems to make fusion happy. I could obviously just post the code for these 2 operations only from the other setup and manually place them into the Gcode post, but the entire point is I shouldn't have to as it all worked on friday just fine before the minor part updates and fusion update. 

I've attached a screencast showing the issue how fusion places the tool near the setup origin instead of the circular feature center like it does on the setup that it's happy with. The same tool is selected for both setups, setup origin is the same, stock size is the same, etc. 

If anyone has ever run into a similar issue and can offer any help, I owe you a beer!

[Marco.Takx]

Hi @mrwhitbread,

Can you share your model so one of us can take a look at it?

To inspect the problem also Autodesk needs te file to do some research.

[mrwhitbread]

I'll happily share the file privately. What's the best way to do that on here? 

Thank you!

[mrwhitbread]

I had this same issue crop up on another part. On the bottom side of the part, I can do the snap ring groove just fine with the same tool in a different setup. Now on the top of the part in a new setup, I'm getting the same error as I was on the part I made this thread originally about. Here's a file I can share, it is the two T2 circular toolpaths at the end that are showing the error.  

[seth.madore]

Yup, so it definitely looks like we still have an issue with certain toolpaths recognizing the direction of the circular faces. I'll open a ticket for this today (or attach the file to an existing ticket if one exists).

As a workaround, you can (thankfully) use 2D Contour. It will require a bit of playing with the leads to get it to not destroy your tool, but some safe values are as follows:

.2 lead in length and radius, 135 degree sweep. That yields this: