How to machine profile/3d & 5 axis tool path

[nnmachine_marshall]

I tried to post this already but I am not sure that it worked. I apologize if this ends up as a duplicate. I need help getting started on this part. I am new to Fusion but I have years of experience programming with other CAM software. First, I am trying to rough out the profile of this part. I haven't found a tool path that will work correctly without undercutting the part because of the peculiar shape. Second, I would appreciate some suggestions on 3D and 5 axis tool paths to rough and finish this part. It will be machined on a 5 axis DMU 50.

Thanks in advance,

~Marshall  

[seth.madore]

Interesting part, for sure. Is there a particular reason why it's broken up into several small bodies, or was that just a by-product of the CAD package that was used to construct this part? 

What is the material, what is the surface finish requirements, what is your workholding? What is the quantity? Do you have any say over what the actual material size is, or are your hands tied in that area?

[nnmachine_marshall]

Thanks for your reply. I didn't realize the part was broken into multiple bodies. They can certainly be stitched together. The material is 6061 aluminum and I can use whatever size stock that is necessary. I am only making five of these for now and the surface finish is called out as 63 rms but it does have to be aesthetically appealing.

[seth.madore]

Yup, the "Combine" makes short work of this area. For general machining, don't overlook the power that integrated CAD gives you. With Sketch and "Project", I was able to make a nice perimeter to control your first couple toolpaths:

The one area where I will admit to being over my head would be when it comes to doing a full 5 axis motion on the 1mm radius around the part. I'll try to educate myself on that one.

The rest of manufacturing is going to be tied to what workholding you have to play with and how many operations you are willing to take. I'd be shooting for a dovetail prep op, one 5 axis mill op and a semi-simple finish op (tabs are awesome)

[nnmachine_marshall]

Thanks for the tip on the project geometry. I plan on holding the part in a 46mm Lang dovetail vise but I wouldn't be opposed to some outside the box fixture ideas. I am curious how you would use tabs for this job.

[johnswetz1982]

Is this a regular DMU50? an evolution or an ecoline? what kind of control? Be sure to add a model of your vice into your model to make sure that you are not going to be milling into or rotating into it. Check out this thread for something similar cnc-machine-kinematic-model-simulation/

[nnmachine_marshall]

This is a DMU 50 with a Siemens 840D control. It has full 5 axis capability. 

[johnswetz1982]

Since your stock does not match your model its tough to tell what your after or where your going to be holding it, but I tend to use 3D adapative from each side rotating 90 each time and repeating the adaptive toolpath. Or add construction plans and roatate 45 degrees each time. It looks like 90 would work for you. Once you manage to get the bulk of it off you can go back with horizontal and contour for your finish paths. Then pick a ball mill for your 3D surfaces and probably a parallel strategy to finish. I only worked on a DMU 50 Ecoline so could not do simultaneous 5 axis but it does not look like that would necessarily be requiried for your piece.    

[seth.madore]

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@johnswetz1982 wrote:

...I only worked on a DMU 50 Ecoline so could not do simultaneous 5 axis but it does not look like that would necessarily be requiried for your piece.    

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@johnswetz1982  well said on the rest of your post. I just wanted to quote your last bit and expand on it. Simultaneous 5 axis in Fusion is currently limited. You would be better off approaching this part in a 3+2 manner. Position to a reasonable angle, lay out some 3d strategies, move and repeat.

[nnmachine_marshall · Accepted solution]

Thanks to all for the suggestions. I will see what I can come up with and post to the forums again if (actually when) I need more help.