Help with picking the correct tool path for my Boomerang

[ghiggsUVQ9T]

Hi there!

I've drawn up a boomerang for my Grandson and have tried several different tool paths to get it to cut the entire blade shape.

I've tried 3D Ramp, but that only cuts the fillet around the blades perimeter and doesn't cut the blade slope. 

Also tried 3D Contour, but that just did some odd cuts to the surface. the blades are apposing shapes with the leading edge at a thickness of 6mm and the trailing edge at 3mm.

Please see the attached file.

Thanks

Glen

[jameshorne0503]

Hi Glen,

Are you looking to make the tool cover the whole surface of boomerang (carve out the top face and the fillets)?

If so I'd recommend the parallel toolpath (pictured) and I ticked contact point boundary and selected tool outside boundary in Tool Containment.

Not sure how you're holding the stock down but if its just clamped down I'd also suggest setting the Bottom Height to Model Bottom with a 0.5mm offset so the boomerang is still held in the stock and you can finish off using a 2d contour with a flat end mill to cut the shape out.

[ghiggsUVQ9T]

Hi James thanks for the quick reply!

I tried that one too but it left big gaps between the cuts. 

Should I be using a flat bottom cutter for parallel, instead of the round nose?

Thanks

Glen

[Marco.Takx · Accepted solution]

Hi @ghiggsUVQ9T,

Within the Preference -> Preview activate Blend.

Create also some surfaces for the fillets.

See My Fusion 360 file in the attachment.

Hopefully, this is what you are looking for.

If my post answers your question Please use  .Accept as Solution & Kudos This helps everyone find answers more quickly!

[jameshorne0503]

A flat endmill would only help on the flat and parallel surfaces. e.g the top centre of the boomerang. Whatever surfacing strategy you take will result in some cusps (if you search on google for 3d surfacing you can find some good examples of people trying to get the best surface finishes). Marco's solution may reduce the cusps but I image some post machine sanding will still be required. To minimise the work, reduce the toolpath stepover (under the passes tab). As you reduce the stepover though, you will significantly increasing the machining time. I'd say a good place to start would be 10% if the tool diameter and if this still looks too rough reduce it further.

You can right click on the toolpath or your setup and select machining time to get an estimate of how long it'll take. This isn't always correct but it can be a good comparison for when you make changes.

If you're struggling to find the toolpath Marco has suggested, you'll have to go into fusion's preferences and enable the preview feature.

[ghiggsUVQ9T]

Thanks Marco,

I had a look at your example it looks good!!,

I tried to figure out how you setup in machining to get the macro folder.

I don’t see that option in the setup drop down. Also need to figure out in draw how you did faces on the filets.

I learn  something new every week 😀

Glen

[ghiggsUVQ9T]

Thanks James,

for the great info.

I'm still trying to wrap my head around how to do the macro setup in machine and faces in design.

Glen

[Marco.Takx · Accepted solution]

Hi @ghiggsUVQ9T,

Within the Design workspace, I created a  2 Workplanes

Make on each workplane a sketch and project the arc edge.

Make from each projected sketch a surface sweep along the top edges like below.

Within the Manufacturing environment, you can check step by step what I selected to get the toolpath. 

If my post answers your question Please use  Accept as Solution  & Kudos This helps everyone find answers more quickly!