4th Axis Indexing not Working

[Anonymous]

I have used HSMXpress for a few months now and have just updated my CNC to include a 4th axis so I am not using the full version of HSMWorks integrated with SolidWorks. I created a test part to mill 6 flats (a hex) onto a cylindrical shaft. The first flat is machined fine and then the 4th axis rotates 60 degrees, but the tool then comes in at an angle as opposed to just horizontally. The simulate button in HSM makes the toolpaths look fine. 

Is there something wrong with my postprocessor or a setting that I need to change to enable proper 4th axis indexing?

[Rob_Lockwood]

since it's a test part, it would be immensely helpful if you could upload/attach the file here. That way, we can give it a look and verify everything is good on the CAM side.

It would also be helpful to know the machine and post processor you're currently using.

[Anonymous]

Attached is the part file. Only 2 of the flats are programmed as I was trying to diagnose the problem. I am using a Tormach PCNC 1100. I'm honestly not sure what post I'm using as someone else set that up.

[Rob_Lockwood]

Yep, everything looks fine enough in there. How about the post processor and machine configuration (where the 4th axis is positioned, is it A/B/C etc?)

[Anonymous]

The axis is in the A-configuration set up on the left side of the table. The post processor is attached. I'm not sure where it came from originally. My suspicion is that somewhere something needs to be changed in the postprocessor or I need a new one that supports 4th axis control.

[Laurens-3DTechDraw]

Please try the attached version of that post.

[Anonymous]

It still seems to output funny g-code. I attached a text file of the g-code. I would assume that the first contour and second contour g-code should look identical, the only difference being an A-axis movement in between contour 1 and contour 2. 

[Laurens-3DTechDraw]

Yes I see.

Now the questions is what machine do you actually have?

[Anonymous]

I have a tormach PCNC 1100 series 3 with a 6" standard 4th axis kit installed

[Laurens-3DTechDraw]

Find the most recent post for that machine here: http://cam.autodesk.com/posts/?p=tormach

You need to do a small edit to make the 4th axis work.

Change this part of the file:

  if (false) {
    var aAxis = createAxis({coordinate:0, table:true, axis:[-1, 0, 0], cyclic:true, preference:1});
    machineConfiguration = new MachineConfiguration(aAxis);
 
    setMachineConfiguration(machineConfiguration);
    optimizeMachineAngles2(1); // map tip mode
  }

To:

  if (true) {
    var aAxis = createAxis({coordinate:0, table:true, axis:[-1, 0, 0], cyclic:true, preference:1});
    machineConfiguration = new MachineConfiguration(aAxis);
 
    setMachineConfiguration(machineConfiguration);
    optimizeMachineAngles2(1); // map tip mode
  }

[Anonymous]

Unfortunately I get the same weird g-code...

[Laurens-3DTechDraw]

I believe the post is set to use TCP but you don't want that. So try this one. 

[Anonymous]

It looks like this will work. I'll try it on the machine later today, but the g-code looks correct. Thanks for the help