Scallop Toolpath issue

[Anonymous]

There is a surface imperfection on our part that is not shown in toolpath preview or simulation.  The "lines" will have to be sanded out as they are able to be felt with a finger nail.  I've attached pictures showing the defect, as well as provided machining details below (for reference). 

Please note:  The set up is rigid, so we should exclude surface variations due to machine, tooling, or operator error.  

Has this issue been noticed before with this particular toolpath?

As the preview appears to be without issue, I can't imagine there is a setting/machining attribute that would be able to resolve this.

Any feedback would be greatly appreciated.

Material:  6061-T6 aluminum

Cutter:  2 flute carbide ball mill (Harvey), .125'' length of cut, .500'' overall length

RPM:  36,000

Feed rate (IPM):  75 I.P.M.

"One-way" direction (climb cutting)

Stepover:  .001''

Tolerance:  .0003''

No smoothing (smoothing controlled on the machine with Dynamics and Contour Smoothing commands)

Tool Holder:  HSK E-25

CNC Machine:  Datron M10 Pro

Thank you.

Best Regards,

Dave Blandino

[seth.madore]

Can you share your file?

Right click on the file and select "Share Public Link"

[Anonymous]

Please let me know if you need further information, as we will have to correspond more privately due to strict NDA's with our customer.

Thank you for your time.

https://gmail217072.autodesk360.com/shares/public/SH56a43QTfd62c1cd968774c34bd1b2c79b0

Best Regards,

Dave Blandino

[seth.madore]

I'm not seeing this in the toolpath. However, I do notice something in the simulation that might give us some clues. This is after T3 runs, but before T5:

Notice that the shape is quite similar to what you are seeing on the final piece?

Here is after T5 runs:

From that, I would infer that your T5 needs to be adjusted in the Height Offset for that tool, or perhaps there are some size variations between T3 and T5.