Hi All,
I have a part I’m making however having trouble programming the feature shown in the attachment.
I’ve managed to break one endmill attempting to pocket it with a 1/16" Square Mill.
Any ideas?
What is the material?
You already know that no round bit is going to make those square corners.
How about making that rounded-corner area a separately-inserted piece and mill the rounded edge before insertion? It would have square corners, too. 
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It’s in Aluminium. It’s actually a 3d Printed part that snapped off my laser machine, thought I’d replace it with an aluminium part.
I’m not fussed about the square corners. A belt feeds through that spot hence the rounded edge so the belt doesn’t get frayed.
I can’t seem to find a toolpath in F360 that will do what I want.
I would consider redesigning it so a 1/8" tool will fit & using a 3D rough & finish strategy.
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What DO you want? If the corners aren’t important, is the overall size? Although a small stepover on a parallel path would round that over, might be faster and less headache with a file.
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It’s a functional part. Basically the belt just has to fit in there and not get frayed because of sharp corners.
As suggested, maybe should edit the actual part and just turn it into an open pocket and then just use a file to smooth out the edges.
Model it like this
Rough it with a 1/8" end mill. Depth per cut about 0.010"
Finish with a 1/8" ball mill, stepover less than 0.010"
The ball mill won’t go past the bottom of the workpiece, so to clean up that bottom edge make the workpiece 1/16" taller than needed, and add a 1/16" base to the model.
2 Likes
That looks exactly like what I’m after, just don’t know how to make the selections of the geometry in Fusion 360. I’ve attached the file for reference in the hope someone can point out how to make the selections I need.
Tensioner.stl (174.9 KB)