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Chamfer (edge break) as machined contours [chamfer rest machining?]

djowen40
Advocate

Chamfer (edge break) as machined contours [chamfer rest machining?]

djowen40
Advocate
Advocate

Hi All,

 

Does anyone know of a way to edge break machine contours (edges) as they are machined rather than as they are modelled?

 

I have included an example below screen shot below. But in essence when machining a tight inside corner the corner is not square. It always a has a radius and an area the tool can't reach. So is there a way to essentially tell fusion to follow the contour that a tool of a certain radius would leave?

So far:

  1. I know i can go into the model and add fillets the same or slightly larger than the tool radius (and possible should to avoid burring the tool and extend its life). However, with a lot of inside corners this can be tedious and if the tool was changed i have to go back and change all the fillets radius. 
  2. By the same token i know i can use sketches to create the desired contour if i don't want modeled fillets but this has the same problems as above.
  3. Assuming the chamfer tool is larger than the radius i could you tip offset to stop it burring in the corner but this requires considerable math.

So is there a way to essentially tell fusion to follow the contour that a tool of a certain radius would leave?

 

The is a simplified example (I would not normally use a 2 adaptive as a finishing pass, but it demonstrate a point):

 

Part to be machined:

image.png

Resulting inside corner due to tool radius:

image.png

Filleting the model edge buries the tool in the corner, like this:

image.png

 

I would like to achieve this, where the chamfer is applied to the radius created by the tool:

image.png

 

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cj.abraham
Alumni
Alumni

@djowen40 2D toolpaths can only be driven by existing geometry, such as the sketch you drew in the pictures. However, there might be something you can do with the setting "minimum cutting radius" in 2D contour. This setting allows you to set the minimum radius for the G2/G3 arcs in internal corners. If you use the chamfer settings to create the right chamfer size and play with the minimum cutting radius value (which will need to be slightly larger than the radius of the last tool to work) then you might get exactly the result you are looking for.

 

Note that there is going to be a catch... the minimum cutting radius can be no bigger than the radius of your chamfer tool. This means that the minimum cutting radius will give you an error if the radius that was machined is more than the chamfer tool radius. Therefore, you may have to lie about the diameter of the chamfer tool (and make it a bigger diameter) to make it work.

 

I'll work on a sample and upload it to give you something to start from, just need some time.

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cj.abraham
Alumni
Alumni
Accepted solution

Here's an example of using minimum cutting radius to control the internal corner. You will need to determine for yourself the minimum radius that you need, but I think this will be a decent way to solve this problemminimum off.PNG

 

minimum on.PNG

 

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djowen40
Advocate
Advocate

Cheers @cj.abraham,

 

So used to using the 2D chamfer I hadn't thought of using 2D contour with a chamfer tool.

 

To would be amazing if this could be added to the model aware 2D Chamfer tool path. I guess for now I will have to carefully check and adjust to avoid cutting side walls etc.

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