Rest Machining Not working

[kmcgheeCMFPG]

Working on a project with a student, we are trying to make a branding iron for his farm logo. We have set up a facing operation, and 1/4" endmill in 3D adaptive to clear out the bulk, I then came in with another 3D adaptive with a 1/8" endmill and checked rest machining, and from previous operation, but it keeps re-cutting the previous operation. Thoughts? File Attached. 

[LibertyMachine]

Turn on "Flat Area Detection" on the passes tab

[kmcgheeCMFPG]

I tried that, but it continues to create toolpaths for everything.

[LibertyMachine]

Oops, forgot to mention the other thing I did; Add some "Stock to Leave" to the rest machining tool (the .125")

With your tolerance and how it calculates the toolpath, both of them set to zero stock is going to result in the second one recognizing that material is there.

Further, Adaptive is not a finishing toolpath. If you are after a crisp clean finish, you would want to use "Stock to Leave" and come in with another type of toolpath, like 2D contour

[kmcgheeCMFPG]

I dont' know what I am doing wrong but even making those changes it still keeps cutting everything.

I am using adaptive right now just to get it cut down to where it is 95% complete, and then I intend to come in and tweak it with stock to leave and contour passes. It is after all just a brand to burn into wood so its not something that needs to be perfect.

[LibertyMachine]

Both adaptives get "Flat Area Detection" turned on. The second one gets some additional stock to leave. Take a look at the attached file

[M&GToolWorks]

I frequently run into this issue as I "rest machine" almost every part I make. Some work, some don't. I have found that nothing I change will MAKE it work. I just delete the operation and start another. I found it is worse for some reason if I start with a derived operation. Easier just to make a new operation, check stock from previous operation and see if it works. Sometimes it takes 3 or 4 tries. No idea why. 

[speedfreakgarage]

I am having the exact same problem right now, and nothing I do (including the advice above) fixes it.  I know for a fact my 3/8 adaptive machined everything (except the sharp corners and small pockets), but my 1/8 adaptive goes and machines everything again, for no reason.  It is costing me double the machining time, making the work unprofitable. Very frustrating...

[CRANDALLPRECISION]

I would like to take a look. I have really good luck with rest machine. Either from cutter or previous ops.

[engineguy]

@speedfreakgarage 

Can you upload a sample file that is giving you the problem ?

Go to :-

File > Export > Select f3d format > Save to a location on your computer > Then attach to your reply.

[speedfreakgarage]

I very much appreciate the offer, but, unfortunately, my time is limited/valuable and I had to abandon the project.  I moved to a simpler-shaped project, where the rest machining works just fine.  It would take me too long to go back, cleanup the model to remove any proprietary design features, and regenerate the CAM toolpaths.  If it happens again on the next project, i'll post it up right away.