Download Fusion360 File
Overview
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In this case study, you will learn how to setup digital stock, perform roughing strategy, finishing strategy, and edit post-processor in Fusion360. Roughing pass is used to take the bulk material from the stock and shape it towards finished form while leaving a specified amount of stock layer. Select the toolpath that will be used to cut the model out of stock. Finishing pass is the polishing stage, that is no different compared to the roughing stage. |
Fusion360 can be used to create positional (3+2) and simultaneous 5-axis toolpath for CNC milling. To begin working in CAD/CAM workspace download Fusion File and import the model. Both Roughing pass and Finishing pass are done from two sides and more.
| Tip: S button allows to summon the “Shortcuts” window where you can search for any existing command/function in the software. |
For example, if you’re willing to adjust the units: Shortcuts button -> type units -> change the unit type.
Preparing the Virtual Stock
Before proceeding to the CAM workspace, it is highly advised to create the stock from the solid body in the Design section (i.e. CAD). This allows readjusting the model within the stock.
Create -> Box -> set the required dimensions for the stock. For the case study, the dimensions of our stock are 110x160x160mm (i.e. or any other size of the stock available).
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Note: It is possible to select the negative value to extrude the stock box below the grid line. |
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Note: To avoid any possible collusions (i.e. tool going under the stock material), we can create a virtual fixture underneath and behind the model to ensure safer roughing and finishing passes. |
Begin working in CAM workspace -> Setup
Please ensure the adjustment between the CNC controller (i.e. Mach3 or Mach4) and the 5axismaker. To do so, we must pay close attention to the creation of the digital stock and verify its perfect fit for the model. Each setup specifies:
- the position of the model
- axis directions which should be set up the same as in your machine’s physical space
- stock outline
- model position in relation to stock.
The stock can be any shape as its possible to create the same dimensions for the digital stock in Fusion360.
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Note: Ensure on the vital points while carrying out the Roughing/Finishing stages: 1. Always refer to the same origin.This technique is widely used to avoid incorrect positioning between work and machine coordinates. Work Coordinates System (WCS) – a global orientation of XYZ axis, part of the setup for every cutting strategy. (i.e. the top left corner of the stock is at X0, Y0, Z0)
Tool Orientation – local orientation of the tool in relation to XYZ. (i.e. part of Geometry Tab for every cutting strategy).
2. Refer to the Setup for every cutting strategy.This option will automatically apply setup details to every cutting strategy, thus avoiding any possible errors.
3. Work coordinate system should be set as per model orientation (i.e. Z up)XYZ directions and zero value should match in both machine' space and digital space.
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If working with a block of material either use "Fixed size box" and specify the dimensions or draw your stock and select it as a solid model. "From solid” option specifies on your pre-drawn stock.
The fixture can also be referenced the same way as the stock itself. We can select it in the Setup Tab.
Select a Tool
Create digital tools that will be used for both Roughing and Finishing passes.
| Tip: enable the Cloud Library, so your tools and post-processors are sharable between computers. Right-click on the user name in the upper right corner -> Preferences
-> General -> Manufacture ->ensure the tick on Enable Cloud Libraries |
In the upper bar Manage -> Tool Library -> click on Cloud or create an individual folder -> New Mill Tool
The window below captures the tools that we have created already.
Select the type of cutter and enter the dimensions of your tool. We advise using the most accurate methods available for measuring tools. (e.g. micrometre, dial test indicator, calliper) For more details, please proceed to the Machine Setup.
Feeds and Speeds are referred to the combination of settings, including speed, depth of cut, the width of cut, and it would always vary on property material. These settings need to be adjusted appropriately with the stock material and the tool length.
Feed Rate: Allows to control the velocity of each machine axis, including the rotational speed of the tool spindle.
RPM (revolutions per minute): It is the frequency of spindle rotation, in other words, how fast the tool is spinning per minute.
Surface Speed: Also known as "cutting speed", it is the speed difference between the tip of your flutes and the centre of the tool.
FPT (feed per tooth): Stands for the relative thickness of each chip, which essentially affects the overall life of the tool.
DOC (depth of tooth): Estimates the height of the chip being cut during machining.
WOC (width of cut): Estimates a relative depth of cut, which also determines how deep the tool is engaged in the cut.
For more information on Feeds and Speeds recipes, please proceed to our official website.
Understand the capabilities of Computer-Aided Manufacturing (CAM) systems for designing complex parts and elements in 3D dimensions - Roughing Pass