I have these two features I’m having a hard time cutting. For an idea of scale this part is about the size of two packs of gum side by side.
The first feature is a hole/slot with 3 degree tapered walls. First I tried a 3D contour with a 1/16" flat end mill but that just left me stair steps.
So then I thought I’d scallop cut it with this really small tapered ball end mill. This looked great in fusion and simulation. But when I took it off the machine the walls look flat. Now I’m thinking maybe I need to buy a 3 degree tapered cutter if such a tool exists, and cut a contour with it?
#2
My second trouble was a similar hole with a 45 degree taper. I tried the 3D contour and got large stair steps. So I thought about using one of my 45 degree 1/4" bits and a 2D contour, but there’s a boss right up on the edge of the hole and fusion only wants to cut with the tip of the tool so 1/2 the diameter of the tool would have to crash through the boss to make the cut. Here I’m thinking maybe I should buy a narrow or long reach 45 degree cutter. Maybe draw some fake contours at different levels in the hole to trick the machine into cutting what I want?
I also planned to try the scallop approach here, have not tried it yet. But I don’t want another flat hole. Again it looks cool in manufacturing and simulation, but I’m afraid I don’t know what I’m doing. Here’s what this scallop looks like:
What’s your advice here? I’m open to suggestions, I’m still pretty new to this. Oh and it’s too late to move the boss :). That ship has sailed for me for now.
Oh and this is my bit I’ve been using for the scallop
Thank you!