I started programming initially with Cimatron, a 10+ year old version of it at that several years ago. Cimatron has an operation called "Remachine" with an option of clean up that worked great. Similar to Rest Machining, you would enter in a previous tool size, say a 1" ball, and the operation would clean out any stock that a 1" ball had left behind. You would then specify values for down and side steps separately. The operation would then clean out all vertical corners/fillets as HSM's 3D contour strategy does, but it would also clean out any corners/fillets that were more horizontal just as the pencil strategy does. The way I do it now is to use Rest Machining Contour first, selecting or drawing up all boundaries encompassing vertical corners, then creating a separate pencil operation for the areas with lower slope. I can't allow the pencil strategy alone to clean out all excess stock in corners, especially in cases of having undrafted walls because the shaft will clash. This approach produces great results but is more time consuming than I'd like. I've also tried using Pocket to do this because it should work as I've described above but I haven't gotten very good results. I think part of this is there isn't a Rest Machining option of From Tool like there is within contour. When I'm working on a part with 2000 surfaces and 20 operations, generating the Pocket operation which looks at all previous operations takes an incredible amount of time. If the toolpath isn't ideal or comes with too much noise, even with the Ignore Cusps value adjusted, I end up spending far too time on just one operation. There are times I need to clean out corners stepping down in tool size 5 times so this can be a very lengthy process which is why I do the 3d contour/pencil approach. I also seem to get much more choppy, gaps in between segments of toolpath than pencil gives me. Photo is attached of Cimatron's Remachine operation (1.jpg) and a quickly made example of HSM Pocket results.
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