problem machining a helix on a partial sphere. ( 4-axis)

[johnptc314159]

how to machine helix groove on partial sphere ++  ???????

i would like to use a 4th axis rotary to revolve this part while cutting a small groove with a ball end mill on a haas mill.

i tried the 2d contour but the z axis stays at the wrapped cylinder size.......see attached.  

known issue: the sphere is hollow and not solid. the helix is a split in the spherical face, if i stitch and patch i lose the path 😞

1. i am not sure how to make a helix groove on the partial sphere ( should be solid ?)

2. i need a cam setup up to mill with 4th axis.

help please 🙂 cheers john

[julia.paganucci]

hi @johnptc314159 , 

thanks for posting! I think what might be useful is turning on beta mode and the using a multi-axis contour with a 4 axis limit. To turn on beta mode, follow the directions listed here. 

I created a new setup that had the z axis pointing up. then created the multi axis contour, selected the helix as the geometry, and enabled the 4 axis limit (see screenshot). 

Let me know if this helps! thanks, 

[johnptc314159]

ok...will try......thanks

[johnptc314159]

no luck. 😞

pdf file shows post error with z as you drew it.

next file is with z axis as you indicated, however that is perpendicular to machine axis and would limit the machining to only one side of sphere

last file has z set as the machine is set but also errors out etc.

???

[julia.paganucci]

hi @johnptc314159 , 

what post processor are you using? 

thanks, 

[johnptc314159]

see attached  haas ngc post   might be a newer one ??

[johnptc314159]

just tried the latest one.........  same 😞

[johnptc314159]

I truncated the end so there is no confusion about machining the pole in 4 axis

[julia.paganucci]

hi @johnptc314159 , 

sorry for the delay. It looks like there's definitely some 4 axis limitations here. I will continue to try and see if there's a way around this. You're using the HAAS - Next Generation Control post right? 

thanks, 

[johnptc314159]

Yes A-axis parallel to x axis

[daniel_lyall]

@julia.paganucci  He is or was using the Haas post with the A axis turned off.

@johnptc314159 I can not get it done properly, a workaround yes or an index of the part on your 4th axis, Just ring UP your local HFO and get them to get you a UMC1000 if only.

[johnptc314159]

long answer and unsolicited thoughts.

1) a axis is always on in the post processor selection box.

2)  this is really basic 4th axis machining  and somewhat amazing no one else has noticed  this.  This makes fusion very limited using a 4 axis mill....hopefully these types of issues get top priority ( see below)

unsolicited comment:  why is there so much effort being put in regenerative design when the basic fusion program has glaring problems,  this is one, as well, as there being no tool to close a sketch.  With such basic 4th axis cam not working maybe fusion should be promoted as a 3-axis cam program so as not to mislead anyone into thinking it has 4th axis capability 😞

ps.........  can inventor machine using the 4th axis ??????????????

pps i have been using autocad/autodesk since the late 1980s..........i am not exactly a new customer 🙂

thanks  john

[johnptc314159]

i am sure john saunders could  run these for me.  The final parts are a heavy tungsten alloy which could make for expensive mistakes.  I plan to run some in 6061 first.

the bigger issue is why fusion cant handle what appears to me a simple 4th axis part.  Its not overly surprising the a $200K 5 axis machine might run them.  The geometry seems pretty straight forward and the coordinates might be generated in excel but how about we get fusion up to speed 🙂

[daniel_lyall]

Yes, all this is being worked on all the time they have a cam team that does this on all the cam platforms genitive is a completely different team.

Inventer cam is basically the same as fusions with different UI.

A lot of what you are trying will be outputting 5th axis toolpaths not 4th axis toolpaths, if you are using a post with the 4th axis turned on it will fail if you turn on show axis in sim it will show if it is 5 axis or not by the angle the tool is sitting.

[johnptc314159]

thanks.   i would like to run the helix with y=0,z following the curve while x and a generate the helix.  does this qualify for 4 axis or what am i missing ??

[julia.paganucci · Accepted solution]

hi @johnptc314159 , 

It doesn't look like we are able to get this done with a 4 axis limited path. Fusion just isn't there yet. 

We are working to improve Fusion's capabilities, so more options will be available in the future for this!

Thanks, 

[johnptc314159 · Accepted solution]

i will reach out to the powers that be.............

thanks