Solved: Advice Needed - Machining Fillets

Anonymous · ‎09-26-2015

Hi,

How does one machine fillets so that they come out smooth? Mine comes out with "ribs" or ridges. My fillet is 10mm in radius and I am using a 4 flute 1/4 inch square end mill. I am also using Radial clearing on the fillet. My material is wood, specifically Poplar. Any suggestions to get fillets to mill smooth?

Cheers!

HughesTooling · ‎09-27-2015

It'll be easier to answer if you can attach a file. In model space right click on the top component and select Export, save a a f3d file.

Mark Hughes
Owner, Hughes Tooling
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Trigg3r · ‎09-27-2015

Sounds like you need to reduce the tool stepover ?

@triggerjolt

@trigg3r

Anonymous · ‎09-27-2015

Hi Mark,

Attached is the f3d file. The fillets come out with "ribs" on them, nothing a little sanding can't fix but would like to get the most of milling it.

Cheers!

Anonymous · ‎09-27-2015

In Passes my Minimum Stepover is 0 mm already.

HughesTooling · ‎09-27-2015

I downloaded your file but there are no tool paths stored under the setup. So I can't really help.

Mark Hughes
Owner, Hughes Tooling
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lacrimacz · ‎09-27-2015

You can reduce the step down value (Passes->Multiple depths) to get smoother fillet.

However I think the main problem is the tool you are using. A flat end mill is not really that good for this kind of feature. Try using a ball-nose cutter instead.

JJ

Anonymous · ‎09-27-2015

Sorry Mark, this one should have the tool paths.

Anonymous · ‎09-27-2015

I do not find Multiple Depths under passes on the Fillet clearing type. I may be missing something.

You might be right that a ball end is more appropriate. I thought by using a ball end that I would get a scalloped pattern left in the wood. I may try the ball end the next time I am at the mill.

Anonymous · ‎09-27-2015

@Anonymous, Totally agree, using a ball endmill is the way to go. The improvement in finish compared to using a flat endmill will be dramatic. The larger the diameter the better, at least within practical limits.

lacrimacz · ‎09-27-2015

Ups, my fault, sorry for misinformation - I forgot multiple depth setting is only available for 2.5D stuff in Fusion 360 CAM.

JJ

HughesTooling · ‎09-28-2015

Thanks for the new file, I wanted to make sure you were cutting across the fillet not along it or my advice would have been to use a ball nosed cutter. With the tool path you're using you can get away with an ordinary slot drill though the advice to use as big a diameter as possible will help. Something that came up on another site is how the direction of cut can make a big difference on wood. The tool path you have is cutting in both directions and that might give a different finish when it is plunging down into the material compared to when it starts at the bottom and moves up.

Another thing to try is reducing the angular step to 0.5° here's your setting.

Here with 0.5°.

Mark Hughes
Owner, Hughes Tooling
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Anonymous · ‎10-04-2015

Using a ball end mill improved the finish. Still room for improvement that I should be able to address in other properties.

Anonymous · ‎10-15-2015

Hey Mark,

I had missed your comment about reducing the Angular Step in the Radial clearing. You are absolutely correct that reducing the angular step and the ball end mill made a HUGE improvement.

Cheers,

Kevin