Incomplete results with 2D adaptive clearing and 2d pockets

[laroot]

I’m modeling an 8” x 13” carved panel for a 17th century chest (Fine Woodworking, Feb. 2011), but I had problems with the “manufacture” module.  So I extracted a 3” x 3” area to play with. 

I sketched the empty area, extruded the area to create a plank, added a decal, sketched the detail, extruded the carved areas down, and deleted the decal.  That “design” result looked fine to my inexperienced eye.

Moving to the manufacture module, I tried both the 2D adaptive clearing and the 2D pocket process but neither worked as I expected them to.  For each, I used the sequence of 1/4”, 1/8”, and 1/16” bits to reach into the narrow arms, but not all of the areas were cut.  I combined the adaptive clearing to rough the cavity and the pocket to finish it but still without complete success. 

I suppressed the pocket toolpaths.  Using just the adaptive clearing, some areas in the arm were not cut at all (even though the 1/8” bit fit into the areas using the pocket process), and many edges were not cut to reduce the “stock to leave” as I cut closer to the final dimension on the smaller bits.

I suppressed the adaptive clearing toolpaths and un-suppressed the pocket toolpaths.  Using just the pocket process, some areas were again not cut at all and the successive toolpaths seemed to ignore the reducing the "stock to leave" settings.

My 3rd attempt retained the adaptive clearing with the 1/4” and 1/8” bits and the pocket process with the 1/8” and 1/16” bits.  But there were still uncut areas and edges that had not had the stock cut to final dimensions.

Is this behavior normal, or am I misusing the tools?

I would sincerely appreciate any comments, criticisms, or suggestions that you can offer.

Very respectfully,
Larry

[daniel_lyall]

Your tool paths are fine, you just need to finish machining the part after the 3 adaptive tool path what are roughing tool paths you need to run a pocket toolpath to clean up the bottom of the part and a 2D contour to clean up the sides of the part example attached

[laroot]

Daniel,

THANK YOU for your response – it was very helpful.  I took time to work through your example and noticed that your contour selection was a single segment while I was going crazy trying to coordinate all the little elements.  That led to a search for how you did that – the contour manager.  That has really simplified what I was doing.  Examples are wonderful!

I guess that my problem is that I don’t understand how “rest machining” is supposed to work.  Using either the 2D adaptive clearing or pocket functions with rest machining, the result doesn’t remove the remaining stock?  That is, why are there uncut segments in areas that are clearly large enough for the bits to cut? 

VERY respectfully,
Larry

3 Stacked adaptives3 Stacked pockets

[daniel_lyall · Accepted solution]

There are a number of settings that affect the tool fit like tolerances, minimum cutting radius, stock to leave, smoothing, and leads and transitions.

2D rest machining does not work 100% all the time as 2D tool paths are controlled by the user more than fusion as they are not model aware, 3D tool paths are can it fit better into some places yes by a tinny amount. 

Now to check it in the simulation start it when it gets to a corner pause the sim then you can swipe right or left when hold drown the LMB this will let you see how well it fits.

[laroot]

Thank you, Daniel; you've been very helpful.

It's nice to know that I'm not alone in having problems with it.  (grin)

Very respectfully,

Larry