something going wrong with feed height & rapid moves

[billbarschdorf]

Hey all, I have an issue with this file I machined yesterday and I can't figure out what the heck is going on with it. When milling the feed height "i think" is the issue? was skimming below the Z0 on all the drill tools, BUT ONLY on the drill tools. The first 3 tools were fine (3/8 FL EM, 2 inch face mill, and the chamfer mill) ran normally, but then when it gets to the drill tools they all have the same issue where the feed height is about .1 or so below z0 and would have crashed if not for me being very conservative and slowing my feed to almost nothing to watch when the tool engages into the material. I ran all the drill tools on the mill to verify and all have this same issue. IF you look a the heights tab on all the drills the (FEED) layer is GONE? WHY and IS THIS the issue being that is not there? There is the default value but it dose not display visually. I had to abort the entire machining setup because I was not sure how to recover from it.

Another issue was the tool movements would never to to a clearance height, The tool would plunge DOWN then try and rapid over to cut/drill location. Almost like the noncutting moves were flipped? Im not even sure how to explain it.

A side note which is REALLY STUMPING ME is the fact that this file is the same file that I ran successfully last weekend, a different part version. The only thing that changed was the parts themselves. I used the same design and CAM file/setup for this version 2 of my parts. Version 1 is the simple version 2 is the one with the extra mickey ears/bolt holes (red part).

I'm including both files. PLEASE HELP!

Version 2 part

https://a360.co/3pLHX3x

Version 1 part
https://a360.co/35ijhsb

[Joshua.Aigen]

Hi @billbarschdorf, Just a guess, but looking at the part could it have to do with the selected geometry is inside of the part. Another way to say it is the drilling operations are before the stock is milled to size for the holes.

[billbarschdorf]

Not sure why that would have anything to do with it? IF I follow you. I do my drilling a lot after facing before feature milling.  and the fact that all the feed moves are above the part where they should be visually and in simulation, all works fine but then at the machine, the Z is wrong.  And this is the same set up I had on the more simple part and all was fine with that run. 

[Joshua.Aigen]

I tried posting the Code, and didn't see anything that would indicate the tool moving below the Z plane other than the drilling. And other than the machines tool offsets being wrong and I'm assuming that was the first place you looked I'm really not sure what is wrong here. Maybe @seth.madore can give this one a look, Thanks Seth!

[seth.madore]

@billbarschdorf what post processor are you using?

[billbarschdorf]

Tormach Path Pilot, Machine is an 1100M

[billbarschdorf]

Hey Guys, I think I figured out what the issue was last night. My G30 position on the machine was set pretty low. Need to confirm this on the next part run so will post back. 

[seth.madore]

Okay, do let us know. Sorry, I meant to post back but got pulled away to other matters...