using side of cutter in 4th axis machining

[customerserviceG2E9S]

Hi,

I am trying to figure out how to machine spiral flutes on a cylinder using the side of the cutter instead of the end.  Anyone know how to do this?

[engineguy]

@customerserviceG2E9S 

Without your file it looks to me in the image that the flutes are set into the bar with radius shape, if so then using an end mill you will just get a series of flats using the side of the tool.

To get a radius groove then I would suggest a radius Slot Mill similar to the image below, if the grooves are not an "Off the Shelf" radius then best way would be to get one ground to size/shape from the next size up.

To be honest for the life of me I am at a loss as to why you can't just run a Ball nose along the bar as it rotates, got to be the easier way to do it 🙂 🙂

Anyway, Hey Ho, each to their own as they say 🙂 🙂

My 2 cents worth 🙂 🙂 🙂

Regards

Rob

[customerserviceG2E9S]

Thanks for the reply!  It is hard to tell from my photo, but the spiral flutes are flat.  What I want the tool to do is drop to the side of the part and create flat spiral flutes along the part.  I can't figure out how to make Fusion command the tool to go anywhere other that the top of the part, using the end of the cutting tool instead of the side.  I hope that makes more sense. I can upload the file later when I get home. 

[Ariel]

Maybe if you had a centreline to the groove, you could use multiaxis contour? 

[daniel_lyall]

Try using a sketch, it would help if you posted the model To attach a file Go to File -> Export and save as a .F3D Archive File and attach it to your next post, if you can not post the file you can PM it to me or say in your next post you can not post the file and one of the Guys that do NDA work will help.

[customerserviceG2E9S]

Sorry for the late reply!  It has been a crazy week.  I came up with a work around for now by adjusting my work offset on my mill.  I would like to be able to do this without having to adjust the work offset, but it kinda works for now.  Here is the file.

[Anonymous]

I made this model to try and see what if anything works and here is what I learned. In order to continuously drive A axis you have to use wrap function,..... when you do that, tool tip points to center of rotation by default.

In order to cut using side of the end mill you would have to use tool orientation instead by picking model edge, face or sketched line that puts tool cutting flutes in orientation parallel with flat on model, using tool orientation and wrap function at the same time is not possible.

Note that my model has a dip in the middle, if I split it, square size measures smaller then one on each end.

I came up with 2 options that clarify the original question, how to machine flats with side of an end mill using 4th axis.

In my test, that is not possible in Fusion on model that has twisted flat faces, if flats were not twisted, you would use tool orientation with contour and circular pattern that would use A axis as an indexer.

1) Blend, or other 3D strategies.

Using tool orientation, A axis is indexed 4 times and 3D tool path is executed at each angle.

2) Two flavors of Rotary tool path

If using spiral option in operation, A axis is driven continuously as tool is driven in X and Z axis.

If using line option, A axis is used as indexer while tool is driven in XYZ motions, so if I pick 1 degree increment of A axis, Fusion executes one pass and progresses to indexing A axis by 1 degree for every subsequent pass until 360 degrees is covered.

Picture on right shows Rotary using line direction of cut completed, followed by circular.

[Anonymous]

Looking at your file, ..... you came up with the only possible way using wrap function.

I tried to refine it a bit, changed tool to bull nose with .03 corner radius.

In operation, I changed bottom height that should eliminate the need to adjust offset at the machine and in linking tab I added .015 vertical radius as entry and exit in case it matters.

Also added full cylinder body for stock.

[customerserviceG2E9S]

Thanks for taking a look at it!  It seems that there is really no easy way to make it work.  I am totally new the 4th axis milling, so  I'm trying to figure it out as I go along. 

[Anonymous]

I encounter these things on Mill-Turn C axis work so anytime 4th axis mill work pops up, it directly compares to what I do daily because process is comparable.

Most of what I do ends up using combination of tool paths and blending heads and tails.

In your case, Rotary is probably the only option that will produce precise result using ball end mill.

[customerserviceG2E9S · Accepted solution]

Finally! I figured it out!

I ended up using a swarf toolpath with 4th axis limit.  If you enable beta mode it shows up as an option.  There were some quirks to work out, but it worked!

Thanks for all the help!

https://autode.sk/2LMKGFe 

[Ariel]

Not sure why, but won't let me access the video

[customerserviceG2E9S]

Oops!  I had the video set to private.  It should work now. 

[Anonymous]

Sooooo,..... before I say "Am I missing something?",....... I am pretty sure I AM missing something. I think I have all options turned on that I care about or those that help me go about my daily business and yet looks like something is missing.

I have no problem making Swarf tool path but it will only post with 5 axis mill or 5 axis mill-turn posts, I currently don't have access to any 5 axis machine so I can't test any code there.

Trying to post with 4 axis mill-turn returns, "Tool orientation not supported" error.

Stock 5 axis PP

Stock Doosan mill-turn PP set to MX

[daniel_lyall]

beta mode is used at your risk, and have you machined a part with what you have shown?

It looks to me to be 5 axes as well with a B, C or a A, C move

[customerserviceG2E9S]

So, I haven't run a part yet, but I did load it into the mill and ran it without a part.  It seems to have worked, but I am getting a strange back and forth in the Y axis.  The Y axis movement is fine, but it shouldn't move at all in the Y as the tool travels along the X axis.  It turns out the toolpath isn't a smooth motion as it travels along the Y axis. 

I am not getting any B or C axis commands.  Just X,Y,Z and A. 

[daniel_lyall]

@customerserviceG2E9S Can you post the model that is working, sometimes a model will work with just a 4th axis continuous toolpath, I have one I can use its tool paths sometimes on other parts.

[customerserviceG2E9S]

@daniel_lyallHere is the file.  I still haven't been able to get the Y axis motion out. 

[daniel_lyall]

@customerserviceG2E9S  Thank you

[Anonymous]

I think the reason why you are getting errors is because you selected tool orientation but have not selected any features.

To clarify potential miss understanding, I haven't bothered with beta option up to this point, why? ... because I don't care for partially functional features in my daily work.

Now, there may be potential use before release of working features so here is my version of "Twisted" Swarf, it will post with mill-turn with Y axis and motions are in XYZC,..... or  XYZA if setup is for mill.

Closer look at resulting code and test on machine is mandatory before making any chips.