Problems with chamfering a profile

[robert.bryan.miller]

I'm going nuts trying to figure out how to do a bevel on the profile of my model. The bevel is also designed into the model. I want a .5mm or 1mm bevel on the edge of this project (file attached). When I run the simulation it looks pretty good but when I cut it on my CNC (Anolex 3060 EVO Max) the bevel is cut far deeper than I want it. Originally I had Top Height set to Model top and the Bottom Height set to -.50mm (I've also tried -1.00mm and .25mm) -- the last iteration I set the cut for Top Height and Bottom Height to Model top and Model bottom and it still cut too deep. What am I missing here?

[programming2C78B]

Does the tool have a .0315" tip in real life? Are you touching it off correctly?

[robert.bryan.miller]

I'm using a Kodiak 2 flute 1/4" (6.35MM) 90 degree bit with a slight (1mm or less) flat on the tip. It has a flat tip that is 1mm (.03937) across. I initially had measured it with a caliper at .8mm -- take your pick. It's sort of tough to get it exact with a caliper.

What do you mean "touching it off?"

[programming2C78B]

How do you set the tool length compensation amount of the chamfer tool on your machine/controller?

If the tool reality matches the program, but the real cut is deeper than the program then you have an issue with touching your tool too low. 

[robert.bryan.miller]

I don't know where that setting is. If the Z is properly zeroed, which it is, it wouldn't matter, would it? Since the cut only goes from top height to bottom height, right?

[programming2C78B]

Of course it matters. If a chamfer tool goes lower then programmed, it will cut an oversize chamfer. 

Stop the tool at Z10. and ensure that it's actually 10mm above your part. 

[robert.bryan.miller]

Sorry, I'm pretty new at this. You're speaking above my level. Where do I make those adjustments? 

[robert.bryan.miller]

Ah -- you're saying I need to insert something into my G-code to raise the bit to Z plus 10mm and stop so I can measure it?

[robert.bryan.miller]

I'm not having any problems with the milling tool -- does that tell us anything?

[robert.bryan.miller]

I think I figured it out. I was using the 2D Contour operation instead of the 2D Chamfer operation. Going to run a test now to see the difference.

[robert.bryan.miller]

So, I was able to get closer to what I want by manipulating the top depth and bottom depth settings, as well as the chamfer tip offset, but the problem is, the simulation still does not line up with what is happening on the machine, IN THE CHAMFER OPERATION ONLY. How would I troubleshoot what the disconnect is here?

[programming2C78B]

99% of my chamfers are done via contour.


You just need to learn how to properly set the Z height of your tool length offset on your machine/controller.

[louis_silverman]

The reason you are having this issue is that you are chaining sometimes the lower contour and upper contour of a feature within the same operation.  Do not do that and your results will be consistent using "2d chamfer" or "2d contours".  "Selected contours" should be your "bottom height" always.