Help with large chamfer?

[antoine.planche]

Hi, I'm having trouble machining a chamfer larger than the tool. I can create a toolpath no problem. The simulation in Fusion is perfect, but the resulting part has lines between each pass. I am using a 2D Contour and increasing the "chamfer tip offset" until I reach the bottom edge. Here is my file: https://a360.co/2FlCUT0

I've tried various different changes with no luck. 

I've tried 4 different tools: a 1/4 carbide 2 flute, 3/8 carbide 2 flute, brand new 3/8 carbide 4 flute, and 5/8 HSS 2 flute.

I've tried ordering the operations from top to bottom and bottom to top. 

I've tried changing the tip diameter of the tool in Fusion. 

I've tried changing how much each pass overlaps each other. 

I'm not sure what else I can try. Hopefully I'm missing something easy. I've ordered a larger chamfer mill that can do it in one pass, but I'd still like to solve this if anyone has any suggestions.

[HughesTooling]

How rigid is your machine and setup? I notice you're conventional milling so is the tool pulling into the job? Have you tried making 2 passes with the chamfer mill, first pass leave a small allowance and climb mill if you can.

Mark

[HughesTooling]

Maybe try something like in the file attached.

Mark

[antoine.planche]

Sorry for the delay in getting back to you. 

The setup was fairly rigid for the piece pictured above. It was held in a kurt vise on a 2019 Haas VF2.  I'm confident that the problem is not due to taking too large of a cut. Most of my tests were just offsetting the chamfer .01-.02" and running a new toolpath. 

The best result is pictured below. That was using a new 3/8 carbide chamfer mill. The finish was identical between climb and conventional. In the picture, I ordered the toolpaths from bottom to top. For whatever reason, that led to the topmost pass having some chatter. The setup wasn't quite as good here. 

I've come to the conclusion that the tools I'm using are not a perfect 90 degrees. I tried walking it in manually and could not remove the lines, they just shifted from the tip of the tool to the shoulder of the tool. I just surfaced the parts I needed to make and in the future I'll just set it up on the 4th axis. 

[dylan_smith]

@antoine.planche The only thing I can think of to why that's happening is that your chamfer tool isn't the same angle as your chamfer.