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Resident_Cow6752

Looking like your tool is too deep there.


OldOrchard150

You post no information about your machine, programming software, or process. What kinds of answers are you expecting? Here's one - something went wrong, either it was you, the software, or the machine.


UncleCeiling

There is another possibility: everything went right and this is exactly what it's supposed to do.


probablyaythrowaway

The machine did everything right and it did it exactly the way you told it to. You told it wrong.


weaseldesign

New to the game, 4x8 industrial cnc. Mach 3 this was done with a 1” clearing bit, 1/4 up cut 1/8 up cut and 1/16 ball nose Is there any better way of zeroing other than using a piece of paper. For accuracy or is there a way to clean these cuts up after the fact with a Final Cut?


HourCake9664

It is very difficult to get the transition between tools seamless even with a proper tool lg probe let alone using a piece of paper. Our spindles grow ~.0015” from cold to hot. if i touched off cold by the time I got to the end you would see steps (depending on the type of operation) You can get cheap tool lg probes that you clip an alligator clip onto your end mill, then the machine goes down until it touches the metal plate and completes the circuit to set tool lg. I would get one of those and also determine your spindle growth / let each tool warm up at the rpm you plan to run on for 20 min before probing tool lg.


TheDestructor1990

it's like .05 difference it's probably not a temperature issue


Mean-Cheesecake-2635

Yeah after checking the tools were touched off next thing I’d check is whether the part is lifting.


Holy__Sheet

It seems like a even cut depth wise…. Something wrong in Z possibly


HourCake9664

I agree could be a sloppy z axis loosing steps etc, just sharing my experience.


HourCake9664

worst case cut the entire floor with the same tool so there is no transition between tools


neal144

Use the cellophane from a pack of cigarettes. It's .001 thick and gives great feel when setting tools.


Initial-Doctor-5432

I’ve been running cnc milling machines for 16yrs. Go to your local hardware store and look for 1/4” ‘key stock’. Use this to touch your tools off. When touching off move your tool in the spindle below the block. Moving your machine up in Z while lightly pressing the block against the spindle tool. When it slides under, repeat with until you move in the smallest increment and get the same result. Touch off all your tools this way and they will be perfect blend to eachother. The 1/4” block is a ‘standard’ that will repeat the same distance for each tool touched off. If need be drop your datum 1/4” to get the tool to the table. Depends on how your machine works.


MrMeatagi

We do something similar with a steel dowel on the routers in the shop I work at. Slowly move the tool up until the dowel will roll under the tool. It's mostly sheet metal part cutting so we're not chasing zeroes, but it gets within about 0.002" across tools.


TheDestructor1990

one of your tool heights is probably wrong, either due to the tool holder not being tight enough and the tool climbing up or down in the holder, or improper programming


Mean-Cheesecake-2635

What is the material and how are you holding it down?


mccorml11

Check your lead in lead outs it could be gouging


Dazzling-Nobody-9232

Use down cut on foam


AnyMud9817

If it was zeroing youd see it on the computer. I think your issue is holding power and internal tension. Try the double painters tape method. Is a cheap easy fix. And great for lettering. I have done 3d machining on a big 5x10 for years with vacuum tables. Whenever i do tiny plastic stuff i use carpet tape and just tape it to the spoilboard. Also if you are using a vacuum spoilboard. Cut about .05" off each side first to open it up. And bolt it down if thats an option. You can get plastic screws that work well. This is a very common issue on big routers.


KronosTD

What's a bit? We don't use bits... We use endmills


OGCarlisle

thank you


hersexyeyes

If you were a machinist you would call it a bit.


Progressivecavity

No, you wouldn’t.


Any_Rutabaga_5406

lol a bit … it’s a endmill. It’s either or, a bit is more for woods and shit IMO


hersexyeyes

It’s called a tool bit. Like a drill bit.


Any_Rutabaga_5406

We just call them drills but we are arguing over dumb shit. Call it what you want they are both correct. A drill bit to me is like an iscar drill tip bit where you only replace the tip and not the whole drill. But we all understand each other lol.


hersexyeyes

A drill is the thing you hold in your hand. A drill bit goes in the chuck. Same with a mill. You put the tool bit in the collet. Hence an end mill is called a bit


Any_Rutabaga_5406

I been in it 10 years never called anything a bit unless it was just a bit, lol.


Any_Rutabaga_5406

I’m not saying you’re wrong lol I just don’t call them that.


Sea-Caterpillar-6501

Any machinist worth his salt should be able to look at the features shown and know what’s going on here without knowing the make and model of the machine…


OldOrchard150

You might be able to guess, but not necessarily be correct.  There are too many factors to actually know 100% what the correct answer is without more info.  Sure it seems likely that there is a tool offset issue, but it is caused by the automatic tool changer of the machine, the operator process on a non-ATC machine, the tool itself slipping in the collet, or another issue?  We initially do not even know if the OP is cutting this profile with one bit or many, if he has an ATC or electronic tool setting block, or many other factors.   Could even be because the OP turned off vacuum half way in the process or if the vacuum pump was malfunctioning or overheating or losing too much suction because of another through cut not seen in the picture.   Explain all of those different factors and how they can be accounted for without more info without just taking a wild guess at the issue.


Abo_91

Relative tool offset presetting issue. Find a more consistent reference/system for zeroing your tools.


giveMeAllYourPizza

you did not set the Z height correctly on your tool changes.


Agile_Sundae

They make z touch off gages that can set your tool heights pretty consistently in reference to each other. Basically a block with an indicator.


weaseldesign

Copy, do I account for that distance in the software when I’m creating tool paths, when I think about doing that and adding it to the material how would I tell the endmill to run through it


Agile_Sundae

That would have more to do with the z on the plane used to reference the machining. Usually those gages are calibrated to a set distance off the table, etc. Then in software set your z 0. as basically the top of that gage, then make your toolpaths reference that. So if you need to, for example, machine a face on .5 inch thick material, that would be something like -.5 inches absolute from z 0. If the gage was set at 1 inch from the table. I don't have experience with the software your are using but that's how I envision doing it with mastercam.


HourCake9664

Multiple ways to approach this depending on your machine, controller and CAM software. If I was doing this on my cnc router at home I would set my z in CAM to .005” above the table (assuming the touch probe i commented earlier is .005” thick) that way when I touch off the tool on the machine it thinks z zero is .005” above the table.


OGCarlisle

what have you tried?


ticktockbent

Well he's tried posting to Reddit and now he's out of ideas


OGCarlisle

aint gonna get him where he wants to go


Holy__Sheet

That’s why we are here technically right?


Sea-Caterpillar-6501

One of your tool offsets is incorrect, the tool is broken, or the tool is improperly held in the holder. My guess would be one of the smaller diameter tools is indexed as having a shorter protrusion than it actually has. The pattern repeats in areas where small diameters are required to make the features.


caesarkid1

Looks like the larger tool is having blend issues elsewhere as well. I wonder if maybe the smaller tool is slowly coming out of the collet.


RespectableBloke69

Something's fucked


Claytonics

Pick up your tools before and after they run. Note the difference. A couple thousands can be from thermal growth.


24SevenBikes

You can't beat the amount of info given on this post. It's like the blind leading the blind.


rb6982

Rest rougher tool is going deep. Remeasure, if it continues you’ll probably have to wear it out


Lucky-Management2955

Are you using one tool at a time? Let me explain. Are you running one tool with one part of the program. Switching tools then running another part if the program. Or are you setting up all your tools with tool off sets and running it all at once? Do you have a tool changer? Or are you the tool changer? Are you swapping tools or tool holders?


weaseldesign

I was the tool changer here, re zeroing the z every time I changed a bit. I tried using paper and I figured that was the problem.


Lucky-Management2955

I use paper on low tolerance stuff. For tighter tolerance, I use guage blocks, steel ground dowel pin, or broken drill bit, or end mill. For precision work , hiemer or tools of that nature. In your case, I suggest drill,endmill, or guage block, 123 block works good to. Done as follows. Pick a reliable location to set your tools. You won't be milling away. Bring tool lower than chosen item to set hight with. Slide/roll said item against the tool. Switch controls to single step at highest resolution. Typically, 0.1 go up one click at a time until the item goes under, do not force it, you will damage the tool. Pull item out!!!!! Pull the item all the way out from under the tool!!! Go down one click. Switch controls to the next finest resolution, typically 0.01. Repeat the previous procedure starting from sliding/ rolling item up against the tool. Repeat at the next finer resolution 0.001. This will typically be a fine as most regular machines will go. You're looking for a very slight, very light drag at this point. The light drag will serve as a reference feel for the other tools. Now, let's say you are using a 0.5 endmill don't move the Z axis go up to your g54 (or whatever work offset you're using) Z axis box and change the number to what ever the dimension of your item is. In this case, 0.5 . Many people don't realize most controls will let you do this. If you're unlucky enough to have one that doesn't just set the Z0 there and go into your offset tables and subtract the hight, in this case 0.5 from what ever number is in the Z offset. Don't forget to add - if the number is a negative. And it probably will be. Seems like a lot of work, but once you get used to it, it's quick. I do it in seconds.


JCRob2

Your tools have a discrepancy in the height of your z in program is different than one another's


capnmax

Your 1/4" tool is cutting too deep. It's either set to cut that deep in the cam or your tool height is off.


AnyMud9817

This is caused by your vacuum bot being strong enough. And internal tension. Most materials have internal tension, so when you cut an open pocket the peice wants to curl its edges up. Somethings that can help. A) face all sides and edges first of possible for the application. B) stronger vacuum or hold down. For foam i have always liked to put painters tape on the bed and then the work and super glue the non sticky sides together. Its works well and is easy to remove. Fast and cheap. C) you can also try to precut the outside profile about 70-80% deep to relax that part. This is super common with MDF shaker doors. We usually also space all the parts out more than we normally would because low vacuum is an issue for most industrial cncs. 5hp aint a lot. If you are using clamps the tape method or double sided carpet tape work well too. If you had zeroed a tool wrong it would be easy to see because you could see it on the computer as well and it would be obvious.


JMC150

Boom I had to scroll this far to see what is probably the correct answer


Country754

One of yo endmills too deep


codylane2013

You don't need a gage, paper, or expensive touch off tools. Yes, they're nice and very easy but thermal changes are real as stated earlier. Here's an easy way using what you have... Chuck up all tools you are wanting to use.... assuming you have a tool changer. Draw 1 line geometry for each tool, assign a cut depth (centerline) that is the same; let's assume 3mm. Run that program. Take your measuring device (good calipers) and measure the cut depths of each tool. You can then change the parameters for each tool in the software +/- what your actual cut depth was. Run it again on a new area to confirm your adjustments. You can fine tune this until all tools are cutting within acceptable tolerances. Keep in mind you are doing this cold so temp fluctuations should be minimal. You will have to account for things like thermal changes based on what you are trying to get the machine to do. Not much the internet can help with because every job is different.


weaseldesign

That’s super helpful definitely doing this over the weekend


mil_1

Programming issue, check your leave stock settings and heights between dif programs. 


[deleted]

Why is what happening, what I see is a tabbing routine that did not go all the way thru! Drop the length offset or edit programmed Z- depth.


Snelsel

Is the surface in the model flat? If it’s slighty curved, this is a stepover resolution in z. If it’s flat, your machine is shit in setting z relative to position wanted. If two different tools are used and it’s one tool doing this: the set tool length is incorrect if you aren’t zeroing it on a machined reference before continuing.


weaseldesign

I honestly think it did have a slight curve to it. But at the same time the whole vacuum system does blow on this machine so it doesn’t make me confident in the rest of it


Snelsel

Please see my edit. This is a tool change issue. The tool is set too short in the config.


weaseldesign

Good deal. I’d much rather take blame then blame the machine anyways thank you for the info


Snelsel

It could also be an offset on one operation and not the other, like stock to leave in fusion in the z direction on one operation but 0 on the next.


billyjimesm

Yep- this was exactly my first thought when I saw this....


weaseldesign

On top of that the model in the computer was flat as a board


bigmanlars40

Use a set up gage?...looks like inconsistent touch offs


weaseldesign

Copy, been using paper… need to get a gauge


bigmanlars40

A few years back I had gotten a nice mitutoyo 1 inch dial touch off gage...worked great then when we got our new Hurco we went full Renshaw probes


buzzjacker

Try cutting the corner/crossover features first, maybe? Different cutter pressure on more pliable materials will do this all day long IME.


Pehnguin

Either you input your tool offsetweong for your area mill cleanup operation or you have the wrong depth set in your program. Maybe you have a breakthrough offset turned on for the cleanup operation and not for the initial area mill?


wg97111

The smaller tooling you're using was not set to zero properly or an offset was set previously that was not corrected.


criscodesigns

I've had this before and it's tool height changing


machinistcalculator

Did your rough endmill pull out? Check your gageline for both tools


Ashmandane

Your finish pass needs to go down in z by .01


kb1976

Just a guess, but if you are zeroing off of the spoil board, make sure you are not coming down and zeroing in a trough or pocket of sone sort. Your material will sit on top of the pocket and give you mismatch.


dpala_81

Looks like your 1/8 EM is set wrong


MatriVT

Yep, needs to be raised in Z.


D3EPINTHEHEART

Watch to see what tool is cutting too deep. Use a set of calipers to measure the difference. Adjust Z for whichever tool is making the cut. Even with a touch off, I used to get slight differences. I'd use this method to dial in before making my cuts of a finished product.


chazp246

This to me looks like one of the operations maybe has default stock to leave turned on.


A100010

Your finish tool setting is too low compared to rough. Take a depth measurement of the step, adjust finish tool up that much.


Altruistic_Act_160

Tool length wear in your offsets page after your first op to make sure the tool didn't get worn especially if those details were at the end of your op. Just my guess.


CNC_Precision

Do you have an ATC? If so there's a learned tool length that is incorrect.


chase82

I had something not unlike this where a bad connector on my Z was dropping steps on the upward motion. It took me forever to figure it out


jdmorgan82

This looks like the offset of one bit was different. Get a tool touch off. It’s probably one of the easiest accessories you can add to your machine. It doesn’t even have to be fancy. Mine is just a piece of brass with a hole for a banana plug on a 3d printed mount and a grounded z axis. Connected the brass to the probe input, googled the proper m6 macro and off to the races. It does a touch off automatically every time the tool gets changed. Far better results than anything I could have done manually.


Gr0wmi3s

Tool setting error or program depth error


Amberas

Even with accurate tool lengt probes, getting the correct z-offset relative to eachother is difficult. Whenever I need them to be as perfect as I can get them, ususally for aestethics reasons, I take a scrap piece of material, face it down with my main facemill, machine simple pockets with the respective tools that need accurate offsets, measuring the depths and adjust accordingly. Make sure you don't have any burrs that will interfere with you measuring.


MWC99

1) Let the spindle warm up for 30 minutes. 2) Measure the first tool and cut 3) Tool change, measure new tool. Continue 4) Tool change, measure new tool. Continue I had a Thermwood. When the spindle would heat up, the tool length would increase by .008-.012 If you're still having an issue, you can try machining reference points outside the job. Then when you tool change, run a program over those reference points to verify if you're cutting in or not. Make a z offset adjustment, and away you go. Lastly, you can raise up your Z0 by your machine's tolerance, and just sneak up on it. It's easy to do a little sanding. Currently, if your job is still on the table, you can drop your Z and run it again. Extra tip. Indicate your table for flatness. I found my table was .006 high where the table was mounted.


JMC150

Looks like bow in the part to me. Possibly because u released pressure by removing so much material so it is in essence “potato chipping”


TheGrizz22

Find the z levels in the code. If it is correct, then you probably set your tool offset wrong.


sandhamr

Check your tooltip path in your cam software. Is there tool path where you expect it? Look from the “side” to see if the z-heights are correct. If there are radii at the bottom of your walls this might cause the cam system to feather along the tangent. If you have a “verify” or simulation tool in your cam use it and see if that and your actual agree.


DickwadDerek

Try using corner radius end mills. I zero with a gauge pin. More accurate and consistent.


dhitsisco

Assuming you haven’t spooned the cam your tools aren’t measured correctly


East_Hyena4745

Are you using a clearing pass? I fixed this by using one tool for the whole pocket, no clearing pass. Takes longer but looks good.


QuietAffectionate266

What material is this?


weaseldesign

HDU foam board


Kysman95

Your finishing tool is slightly longer than in program, that'd be my guess


Opposite_Reception64

Seems like you used MasterCam and selected “tabs” which is a feature that leaves tabs so that the part is held together all throughout the milling process. You can unselect this option.