So here is what I found best to work out the tool. (I don't think Fusion was made by those w/ "old" machining knowledge) So far it has been humorous, at times, it is faster to machine a complex form manually, rather than bicker with Fusion to try and convince it to make what it views as a strange cut. Been doing it this way for years and started out machining manually with dividing heads. Works the same, I program in sections, and rotate as necessary. Keep in mind, I do not have a full 4th axis, but rotate my work on a dividing head. Here is what I wound up doing with my recent piece of tooling. Typically you can get away (sometimes!) with a bigger diameter tool, providing a more rigid cutter. If your part has sloped walls, perfect! Often with 3D forms however, you will transition through many faces, and that is when issues crop up.īull endmills, however, are great for form work as the tool is cutting on the outside edge. Easy to do in a 5 axis, not easy to do in a 3 axis. Ball endmills are best utilized with a 10-20 degree angle (I usually shoot for 15). The majority of ball endmills are not center cutting, and as at center they are "not" turning, they cut poorly. They are common for form work, but typically in a multi axis machine. Ball endmills really are not meant to be used perpendicular to the work piece. I see a LOT of people posting using 3D ball endmills for 3D form work. The few simple tips I am going to post really apply to any 3D machining.įirst, Ball endmills. And honestly, tying it specifically to a model tends to change people's understanding. The model would be excellent to share, because this would all be much more informational, but due to ITAR, customer requirements, and lots of other political BS, it is best left out. The part I am working on is a cylinder of sorts, with lots of faces, protrusions, and goofy stuff the customer dreamed up. If you have any questions about Smoothing, this is an excellent basis to begin: This is not meant to be a comprehensive post by any means, but I just want to share a few things that I have found worked pretty well. There isn't a flat or parallel side on the part (except the end), and often times it is a frustrating and time consuming guess and check process to determine what works. Lately I have been working on some tooling for a customer, which has really given me a run for my money attempting to use Fusion. Most of this experience, albeit limited, was on higher end machinery, like a Hermle 5ax. I do not have much experience in mold work, but have worked in stamping most of my life and have done some pretty complex form tools.
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