Why did this operation fail?

[timothyhinessr]

I had an issue this afternoon with a contour finish pass where the tool tried to take a WOC of approximately .2 instead of the .01 that I left on from the previous operation.  This was the first time I ran this program so before anyone chastises me for not running it above the part first, I should have, and paid for it with a brand new end mill that is now chipped.  I've been using the same post processor with my Tormach 1100MX for several months now and have never had something like this happen.  The operation simulated perfectly with no indication that this would happen.  Running it for the first time, I was going slow and watching carefully and the tool went to where it was supposed to prior to entering the material so I thought it was going to be okay.  All the prior operations behaved appropriately.  I have a large lead-in programmed because I have cutter compensation on for the operation that requires it.  After the incident, I did run the operation above the part and it followed the correct tool path all around the part but at the wrong WOC.  I have no idea what went wrong here but it seems like there may have been some erroneous G-Code generated.  If it was a programming error on my part, the simulation should have caught it.  I've included the program as it was when I posted it.  I'll try re-posting it and seeing if anything changes but would really like to know what happened if anyone can figure it out.  Thanks!

[timothyhinessr]

I think I figured out what happened.  Tool 4 was a new tool and although I properly identified it in the tool table in Fusion, I somehow failed to enter the diameter in the tool table on the controller.  The prior roughing operation with it worked fine but when the controller needed the tool diameter for cutter compensation for the finishing contour and there wasn't one entered, it cut too deep for whatever reason.  I'll run it again tomorrow with the tool diameter in the controller to be sure but I'm pretty confident that's what happened.  

[seth.madore]

Yep, that will do it. Without the radius of the tool set in the controller, the toolpath is going to cut as if your tool is zero in diameter. Expensive lesson to be learned, for sure. Is it possible for you to use "Wear" compensation? I prefer that method myself, since I never have to remember to put in the tool radius, as it's just "zero" to start.