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how to 2D chamfer a web structure without overloading the chamfer tool

designingberlin
Advocate

how to 2D chamfer a web structure without overloading the chamfer tool

designingberlin
Advocate
Advocate

Hi all,

here is a question. I've a lightweight shell / web structure for  CNC milling. The machined pockets will have some corner radius that I don't want to model (performance issues in fusion with seberal hundred fillets).

I still want to add a 2D chamfer to the machined pockets. This may results in a bad situation for the chemfer tool:fusion3.jpg

 

The chamfer tool tip will machine into the corner. Not good.

 

Is there a clever way to machine and chamfer such a shell / web structure without modeling all the corners?

 

I can use a large diameter chamfer tool and adjust the tool tip offset for the chamfering operation to match the actual fillet radius. That works, but the chamfer tool will run into unwanted high chiploads in the tight corners and for shallow pockets the chamfer tool tip will penetrate the pocket bottom face ...

 

For now I do model all fillets, but it slows down fusion a lot and minor design changes require reselection of corners more often that I want.

 

Thanks for your suggestions!

 

Happy CAMing.

Stefan

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HughesTooling
Consultant
Consultant

what performance problems did you have with fillets? Where you trying to fillet the sketch? You should always keep filleting in sketches to  minimum and fillet the model, and always add fillets at the end of the design. File's attached, I've set the fillet to 2.0mm and as I've enabled history you can easily edit.

Capture4.PNG

 

Mark

Mark Hughes
Owner, Hughes Tooling
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designingberlin
Advocate
Advocate

Hi Marc,

the performance issues come up when recalculation more that 400 fillets as 3D features. I'd like to fillet in the 2D sketch, but since the structure was generated with the web command, there is only an underlaying sketch to define the web center lines. The acutal triangular structure is purely generated by the web command.

There is no 2D sketch to put the fillets in.

 

Thanks,

Stefan

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HughesTooling
Consultant
Consultant

OK are there more components or are all 400 fillets in one body? Calculation of 3d fillets is way faster than 2d sketches so not sure what to suggest. If you have several components are you following Rule 1#1 and keeping the components self contained so any fillet features are just for the one components, don't share the feature across multiple components\bodies.

 

Have you tried using 2d contour for the chamfer and setting a minimum cutting radius? I think the radius is at the tip so you'll need to do a bit of math or sketch to get the rad at the contact height.

 

Mark

Mark Hughes
Owner, Hughes Tooling
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dylan_smith
Autodesk
Autodesk

@designingberlin Your best bet is to model the fillets into the part along with the chamfers. Another thing to remember is to make sure the radii in the corners are what you think they are, if they are smaller than expected you will get a heavier cut in the corners. Is this what you meant? 



Dylan Smith

Manufacturing Specialist

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designingberlin
Advocate
Advocate

Modeling the fillets is my current apprach, but I't really tedious and slows down overall fusion360 performance. 

 

Once the fillets are modeled, everything is fine - I still want to avoid the modeling part of it. Mainly because that approach seem to be volatile: small design changes in the design make the fillet operation forget about an edge and one edge es to much ...

 

Thanks,

Stefan

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HughesTooling
Consultant
Consultant

Did you look at the 2d contour option. Don't know if you know it has a chamfer option, with some experimentation with minimum cutting radius you should be able to get what you want.

 

Mark

Mark Hughes
Owner, Hughes Tooling
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