Form tool / post processor not working correctly

[phillip.r.prentice]

Hi -

I've created a 90 side-cutter form tool and applied this to my CAM.  Simulation looks perfect, however when I go to run the part on my CNC (CNC 6040 desktop router), the cutter never reaches the part.  I've correctly zero'd XYZ to the center of my tapered dowel.

Any suggestions?

I'm using mach3 PP.  Attaching the file as well as the G-code.

Thanks,

Phil

[engineguy]

@phillip.r.prentice 

From what I can see with a quick look at your file it looks like you have generated the code using your 1.25in cutter and you have your 1.0in cutter in the machine, the code in the X axis is exactly 0.125in further away in the X using the 1.25in cutter code 🙂

Hope that helps 🙂 🙂 🙂

Stay Safe

Regards

Rob

[phillip.r.prentice]

HI Rob -

Appreciate the reply!  

Sorry, I've been playing around and banging my head on this for 10 hours so I attached the wrong G-code.  Even with the correct 1.0" cutter setup in fusion, the edge of the bit doesn't even come in contact with the dowel at the maximum depth in trace1-4.

What's interesting is the more I reduce the diameter in the Tool Manager, the closer the bit comes to the material.  Setting the diameter to say 0.001", the bit plunges in too deep,  but at least it starts cutting.  I'm just not sure how to go about debugging what is wrong here.

Things I've double/triple checked:

1. The dimensions of my dowel (1.15" tapered at 0.4 degrees)

2. I'm zero'ing the tool by using the tip of the dead center which is mounted in the 4th axis (for X/Y).  For Z, I'm using the edge of the cutter to the center-line.  (This matches what I have setup in fusion 360).

Other than tweaking the diameter of the tool, outputting code, running and repeating is there a method I can use to just "trick" mach3 and adjust my X home position a little bit each time until the generated code makes contact?  Then I think I can add up these little adjustments and set the tool diameter to match ?  Or any other suggestions....I'm at a loss here.

Thanks,

Phil

[engineguy]

@phillip.r.prentice 

The code looks correct so it must be the setup at the machine, especially the X offset value, check if you have any X value in the G54 settings, if there is an X offset value in there then it will move the whole program over in the X.

A quick way to test would be to remove the G54 at the start of your code and see if the program does move over to cut the stock.

Stay Safe

Regards

Rob

Regards

Rob

[phillip.r.prentice]

Removing G54 didn't change anything, however changing the diameter from 1" to 0.5" did.  I'm wondering if the Tool library has a bug?  Perhaps the diameter should say radius?

[seth.madore]

Where is the sketch you used to generate the Form Tool? I didn't see it in your design documents

[phillip.r.prentice]

I created the form mill in another document.

Attaching that here.

-Phil

[seth.madore]

What's the major diameter of the form tool supposed to be?

When drawing a Form tool profile, it's a 1:1 ratio. Draw it to full scale. By my measurements, your tool should be 2.024" in diameter?