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- Create Toolpath

This page is the process for Creating tool path, in week 12 Molding and Casting. I made the tool path by Fusion360. The Process is below.

1. Create Toolpath

1-1) Setup

  • Setup
    This time, the origin is selected as the material top left corner.
    alt text
  • Stock setting
    I revise the all number to 0 and confirm the material size is same as mold model size 92(W)x76(D)x39(H) mm.
    alt text
  • Post Process (default) and Click OK.
    alt text

1-2) Creat my rough toolpath

  • Choose 3D Pocket Clearing alt text
  • Set tool / Feed & Speed
    • Tool: Select 6mm Flat end mill
    • Coolant: Disabled
    • Spindle Speed: 15000 rpm
    • Ramp Spindle Speed: 15000 rpm
    • Cutting Feedrate: 1200 mm/min
    • Feed per Tooth: 0.04 mm
    • Lead-in Feedrate: 1200 mm/min
    • Lead-out Feedrate: 1200 mm/min
    • Ramp Feedrate: 200 mm/min
    • Plunge Feedrate: 200 mm/min alt text
  • Tool & edit
    I measure the mill and edit. alt text
  • Geometry (Default) alt text
  • Height (Default) alt text
  • Set Passes and Stock to leave
    • Maximum Roughing : 0.5mm
    • Stock to Leave (Radial Stock to Leave: 0.5mm, Axial Stock to Leave: 0.5mm)
    • others (Default) alt text
  • Linking / Leads & Transitions / Ramp (Default)
    alt text
  • Actions > Simulation (Machining time : 34min) alt text
  • Actions > Post Process
    • Post: Roland RML/ roland rml
    • Machine type: MDX-40 alt text

1-3) Creat finish toolpath

  • Choose 3D Pocket Clearing alt text
  • Set tool / Feed & Speed
    • Tool: Select 2mm Ball end mill
    • Coolant: Disabled
    • Spindle Speed: 15000 rpm
    • Ramp Spindle Speed: 15000 rpm
    • Cutting Feedrate: 1200 mm/min
    • Feed per Tooth: 0.04 mm
    • Lead-in Feedrate: 1200 mm/min
    • Lead-out Feedrate: 1200 mm/min
    • Ramp Feedrate: 200 mm/min
    • Plunge Feedrate: 200 mm/min alt text
  • Tool & edit
    I measure the mill and edit. alt text
  • Set Geometry
    • Rest machining
      • Source:From Previous operation
      • Adjustment: Machine cups
      • Adjustment Offset: 0mm
    • Others (Default)
      alt text
  • Height (Default) alt text
  • Set Passes and Stock to leave
    • Maximum Step over : 0.5mm
    • Maximum Roughing : 0.2mm
    • others (Default)
      alt text
  • Set Linking / Leads & Transitions / Ramp
    • Ramp type: Plunge
    • Others (Default)
      alt text
  • Actions > Simulation (Simulation Machining time: about 1 hour and half) alt text
  • Actions > Post Process
    • Post: Roland RML/ roland rml
    • Machine type: MDX-40 alt text

2. Important point I learned.

  • It it important to consider Chip Load, Plunge Feedrate and WSC (Stock point). -> The details in Week7.

  • Tool edit:
    In Fusion, you can check tool paths for collisions. It is important to edit the size of the tools you use correctly, because if the tool settings are incorrect, interference checking will not work correctly.

  • Rest Machining in finish tool path:
    • It is important to create the Finishing tool path with "rest machining", otherwise you should lost your time.
    • In my case, as the mill was moved in the air (not reached the body), I noticed something wrong, and I stopped and discontinued the tool path. I edit the finish tool path with adding "the rest machining", then mill restart, then the mill is reach to body. The finishing milling is success and the simulation time has been reduced by 3.5 hours.

3. Trouble & How I solved

3-1) Warning by Stepover

Durning create finish tool path, I got warning of Step over.
alt text

I refer to Fusion360 community and I learned "It appears that the step over settings are limited to the radius of the tool or less.

Refer to cad cam lessons.com, and set the step over under the half of the radius of the tool, in "Set Passes and Stock to leave ". Then I could create path without warning.