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CAM post process failed (Mach3)

Anonymous

CAM post process failed (Mach3)

Anonymous
Not applicable

I was excited to try the adaptive clearing MOP for a first time.  it showed a 50% reduction in machining time vs my typical CAMBAM generated code.  my 3-D part uses the adaptive MOP for rough out and then the parallel MOP to finish.  I couldn't create a .NC file, just a .TAP file, but renamed it for MACH3 loading.  I noticed the Abnormal button flashing on and off while loading in Mach3, which never happens with CAMBAM files.  turns out the adaptive clearing portion never loaded and it only ran the finish step.  I tried just one MOP at a time and sure enough, the adaptive failed and the parallel would process.  I was getting G90/G91 errors (???).  I never generated gcode with CAMBAM that didn't run, so am clueless as to what is happening.  with Cambam I never had to even look at the Gcode or modify it.  this part generates like 500K of code.  the 1001.tap.failed file mentioned another report for details, but I can't find that.

with further testing it seems the .TAP file name doesn't matter to Mach3, right?

my adaptive clearing step seems fine within fusion.  the simulator runs it fine.  one post suggested using a Linux post processor rather than the Mach3mill, but that didn't fix anything.  I am using all defaults in post processing.

 

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LibertyMachine
Mentor
Mentor

Please share the Fusion file here:

File > Export > Save to local folder. Return to thread and attach the .f3d file in your reply


Seth Madore
Owner, Liberty Machine, Inc.
Good. Fast. Cheap. Pick two.
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Anonymous
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here is the file, half of a kayak paddle.

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LibertyMachine
Mentor
Mentor

The error with posting is that you are using an invalid coolant code "Suction". The post is not configured for that function, although it CAN be configured.

Regarding the file size: Turn on "Smoothing". With your tolerance and smoothing set to .004" (which is quite large) your file is reduced by 50%, going from a 3.2MB to a 1.54MB cut

I tried reducing the tolerance to .001 on both and it crashed on me. Twice.

 


Seth Madore
Owner, Liberty Machine, Inc.
Good. Fast. Cheap. Pick two.
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Anonymous
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wow, I clicked on suction simply because I am cutting wood.  my machine has no control over my vacuum system.  I manually turn it on before starting.  I will fix this and see what happens.  thank you.

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Anonymous
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I changed "suction" to "disabled" and thought my problems were over.  the first operation, adaptive1,  worked, but the finish step is failing.  again, it is the G90/G91.1 thing.  when the step starts to run it stops to insert the cutting tool, then crashes the table limits [external E stop] about a 2 feet away while trying to rapid to the initial cutting spot. [ G0 X-2.0003 Y0.8392  ]

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Anonymous
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Seth - comparing gcode that worked and code that didn't, same opening code lines, then stepping it thru, I discovered what I believe my issue was that after the initial tool change it raises the tool to Z=0, and during the rapid to the first cut, vibrations were setting the Z limit switch off.  I've never had problems with my limit switches before, so didn't suspect them.  the code that ran had a short rapid move before first cut, the problematic one traversed the whole 48" table.  well, I'm learning about gcodes.  didn't really want to.

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daniel_lyall
Mentor
Mentor

One thing you can try is you can do a home in places on the Z axis by turning the pin off for it homing will still work for the X and Y axis, you will have to set the Z to a safe spot then hit home Z. Then when you run the code if you have G28 turned on the the Z should lift up to where you set it and do the normal start stuff, then move to the first cut position and start cutting.

 

Now if before the first tool change if it goes to home that's good then goes to the next start position, if it does not go to the start position  you may have a offset stuck in mach if this is so it will goto where it finished cutting before the tool change then go to the start position of the next cut.

 

If it does this what you need to do before you do anything on it, straight after you start Mach3 goto the MDI screen and put G40 and G49 into the mdi and hit enter then go home the machine and set your work zero, if it happens again after doing this, it's something else.

 

This sounds totally stupid But I have seen it happen on the same machine a few times after Fusion has been used on it I almost got punched in the head last time it happened a $100 endmill got broken.

 

I can not find what is make it happen.


Win10 pro | 16 GB ram | 4 GB graphics Quadro K2200 | Intel(R) 8Xeon(R) CPU E5-1620 v3 @ 3.50GHz 3.50 GHz

Daniel Lyall
The Big Boss
Mach3 User
My Websight, Daniels Wheelchair Customisations.
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