Form Tool CAM challenge

[jasonUUJF4]

HI Gang. I know it's simple... what the heck am I doing wrong???

I want a 33 deg chamfer tool that made into a form tool to shape one long edge of a part along with the two fillets on the corners. See attached photo below.

Note how the rounded corners are not getting cut with the form tool.

 This is made with a simple 2D contour. I THINK I need either a 3D tool path? The file is attached as well.

I'm sure It's simple. I would love any advice or help anyone has time to offer.

Thanks a ton in advance!

[engineguy]

@jasonUUJF4 

Hmmm, nothing in Manufacture and no Form tool to test so not able to help 🙂 🙂

[programming2C78B]

If you just want the 2 corners to also be cut, look into the min cutting radius of the tool and ensure that the 3 segments are selected. A 2d contour is all thats needed.

[jasonUUJF4]

OOOPS! That tells you how advanced I am.  lol

Attached it the modified file. (Sorry about that)

There are 2 tool paths.

1. Using the form tool.

2. Using a strait flute cutter with the tool orientation altered to the chamfer angle. This solution is really close to my desired final goal, BUT I don't have the 4th axis, that's why I made the form tool.

I think I need a 3D tool path because the rounded corners are perpendicular to the angled face?

I know the difference is subtle, but I'd like to get this correct.

Cheers and Thank you!!

[seth.madore]

The form tool and toolpath is correct for the long section of the angle, as you are aware. The issue lies in the corner, where it's a compound angle and the tool used is not correct.

That said; 3D Contour (and all 3D toolpaths, if I'm not mistaken) won't work with Form Tools, you would need to define it as a Dovetail Mill.

[jasonUUJF4]

Thanks Seth!!! Great to hear from you. 😊

Now that I know I need to reclassify my tool, can you recommend the best approach to this 3d tool path? Can I just select some geometry or should I create a sketch of some sort and use that to guide the tool?

I know is amazingly simple to you smart folks, but CAM is still something I am learning at a snails pace. 

Thank you!!!!!!

[leo.castellon]

Any reason why you couldn't just flip the part around and machine it with the bevel on the top side and then just use a ball end mill? Yeah, you have a small chamfer around the part, but realistically, that could be hit with a file and still be acceptable in most circles.

LeoC

[seth.madore]

What is your actual tool, is it an "off-the-shelf" dovetail cutter or is it something that's been custom ground for you?

[jasonUUJF4]

Thanks Leo. This side needs to be up because there's about 5 other operations as well.

[jasonUUJF4]

Thanks Seth.

Attached is the exact cutter I'm using. It is an adjustable 2 flute insert chamfer cutter made by Amana. I made the arbor to run on the CNC. You can see that the form tool/profile I made incorporates the arbor nut on the bottom of the arbor.

FYI.

-This is for cutting walnut (wood)

-I've made hundreds of these parts but have taken this opp offline to a second machine.(My hope is to keep it on the cnc)

-I don't have all of the other operations,fixtures or full assembly shown.

-Before anyone shows concern about the spindle being used, I have a 15HP Hiteco HSK spindle that is more than capable or running this cutter at the manufactures recommended feeds and speeds.  🙂

-I am holding the part with vacuum only so I have full access to the parameter.

And lastly. I am BEYOND appreciative of all the information anyone is willing to share with me, so thank you to all in advance.

This is the finished product link if it's helpful

[seth.madore]

Does your machine have a tool changer and would you be okay with an alternate solution for the corners?

[leo.castellon]

Nice knives.

LeoC

[seth.madore]

Full radius key cutter with 3D Contour, selection is just "Touch/Avoid" (set to touch the two radii)

 

[jasonUUJF4]

Thanks Seth. I never would have thought of that. WOW.

However, this is not an upgrade to my current solution I don't believe. I really would like 1 tool path that hits the 2 corners and long edge in one big slice. If that's not possible within fusion I'm better off doing this cut on the the other machine.

Does your experience lead you to any other out of the box solutions?  🙂

[jasonUUJF4]

ha! Thanks. I can only take credit for the wood stuff though. Lots of other smart people doing the metal work. 🙂

[seth.madore · Accepted solution]

The issue is that the angle on the planar face is different than that of the radius. So, unless you have a magic adjustable (on-the-fly) angle tool, it isn't possible with that tool. Because it's a Form Tool, we can't use it for 3D Contour, so you'd have to define it as a Dovetail mill, understanding that it's not going to know that there's a large diameter at the bottom...

[jasonUUJF4]

Thanks again Seth. At the end of the day, I think I need to change plans.  😞

I really appreciate your input.