Swarf Toolpath cutting incorrectly

[Tim83WNR]

Need help ASAP! I am cutting the outside of a profile on my part with a swarf toolpath and I am having issues with getting the geometry to line up like it should. It is almost like the toolpath is offset from the model and leaving material on one side and taking to much on the other side. I have went through and double checked all of my offsets and also checked the MRZP on my machine and can't seem to find anything that would make this happen. Here is a sample of what the issue is. As you can see in the picture, the outside walls are two different sizes when they need to be the same. The pockets are already machined into the part and bottom is already finished. Cutting the outside profile is the last thing that needs to be machined.

 

[seth.madore]

Ouch, that's not good. Can you share the file here, or more details? What machine is this on, what post are you using?
Is this being done in the same (Fusion) setup as the rest of the part? If not, does the Setup share the exact same WCS? Where IS your WCS, btw?

[Tim83WNR]

I'm not able to share the file. The machine is a Haas UMC 1000SS. The post processor is Haas Next Generation Control with UMC 1000 selected as machine model. The WCS is located off of the center of the bottom of the part. This Op is being done in a different set-up than the rest of the part.

[dylan.smith]

@Tim83WNR Sounds like it could be a referencing issue if this operation is being done in a different setup. I'm assuming you're referencing of known machined features?

[Tim83WNR]

@dylan.smith Yes, I am using know machined features. The part is touched off on the bottom of the part and located with the drilled hole locations that are already machined on it from previous operations.

[dylan.smith]

@Tim83WNR assuming you have orientated your part of a known feature also? Drills often don't cut perfectly to size so this could contribute towards your inaccuracy. Without seeing a CAD model or seeing the way the parts referenced, its hard to comment. I would be surprised if its a Fusion error apposed to a setup error though.

[Tim83WNR]

@dylan.smith  I have attached a few pictures below on how it is being held and how it is located.

Y axis is located along the side of the part. It is swept in with C axis

Z is referenced off the bottom of the part. That is how it is being held on the fixture.

This is what the part looks like in the machine.

This is the Anchor block that the part mounts to. The little bosses hold the part in place and are used to mount the part to the block. The bore in the center is lined up with the center of the bottom of the part.

[dylan.smith]

@Tim83WNR I'd suggest maybe doing some manual checks, or even running some surface inspection if its possible to set the part back up. To my knowledge the only error that could cause this is a user error, a post error or a set up error on the machine. Without you being able to supply me with more details on the project its difficult for me to make a judgement.