The island of Kauai is the more geologically dramatic in Hawaii’s chain. More to the point, it should be one of the most dramatic topographies to machine.
I figured this would pose a good challenge for me to learn more about Fusion 360 as well as the limits of my XXL.
Unfortunately, there has been a ton of “shut up and color” time waiting for the 3D adaptive clear to compute in my CAM workflow. There are a few issues that I’m not totally clear if I see a good solution:
Kauai has tons of steep canyons and valley that at my current scale might cause the collet nut or spindle housing hit when plunging the end mill to the bottom of a valley. Can Fusion be programed to consider this in its toolpath? If so, how? I’m thinking that no matter what you do it will be somewhat imprecise as you will have to manually measure how much of your endmill extends out of the collet…
29 Hours of Machine time on a 3D adaptive clear and 1/4" ball nose endmill… the bit is traveling 1.588 MILES. The computation time here is insane. I’m going to bed turning on an option and waking up to see if it will increase or decrease the time. Is my issue here scale, the number of facets, or an option I simply don’t have selected? I’ve messed around a lot with flat area detection, ordering by depth, machining cavities, etc…; I haven’t been able to get a successful computation using “Most” on the Stay-Down Level, but “total rapid time” seems to only be 1hr 8mins so I’m not sure how much this would help…
A finishing pass… I haven’t been able to get a parallel tool path to successfully compute using rest machining on this model. Not sure if there is something weird going on with rest machining resulting from the super complex 3D Adaptive step, but it just generates an error when I try to turn it on. With Rest Machining off and a 1/8" ballnose endmill and a 10% stepover results in 258hrs of machining time… the “Steep and Shallow” toolpath in Fusion 360 sounds like it would work well in this application… should I buy it and try that? or is trying to machine this using a square bit (maybe a downcut bit) and hand sanding a better idea?
Practically speaking; how frequently should I allow the carbide compact router to cool down? How many “miles” are the S3’s motors good for? How many 1/4" ball nose endmills would this job eat through going into something like walnut or koa wood? I’ve never used only the first 25% of a bits cutting face for this amount of material removal, is there a better way to engage more of the flute without creating a dangerous stepdown value?
Thanks in advance!