It is a standard Surface rough pocket toolpath. Removes large amounts of stock. With a flute length of 5/8" Max. if you get under the inserts you have problems. If you increse the stepover it will leave stock islands on a number of levels then come back and get them later (problem), increseing the depth of cut, sometimes exceeding flute length.

The tool I am useing is what we call a button cutter. Basicly 3" bull nose with 1/4" Rad. inserts (non center cutting) Insert height aprox. 5/8".

Like I said from "experiance" MC will leave areas on the floor if you use a 80% step over. In theory it shouldn't. You can see these islands in Verify too.

Drill bits are designed for axial forces not lateral ones - they fall to pieces when driven laterally. And drill bits have a vital feature end mills do not: the ability to cope with the varying tool speeds radially, and particularly the ability to drill in the center where tool speed is zero. End mills simply are not made for that!

V bitstepover

Endmills also have hardened shanks like taps and and drills do not. Drill chuck jaws are designed to grab onto and dig into an unhardened shank.

I generally use 80 to 90 percent radial for roughing. I also often run into the same problem, but not that often. We typically rough with a 1 inch tool so that might be the difference. Zig zag tends to be the most predictable, but with many scenarios it isn't a very good option IMO.

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We are cutting Aluminum billets (66 1/2" X 59 1/2" X 13"), current job, they do get bigger. It will make a form tool for a car or SUV headliner.

I have tried all pocket pattern types, anything over 70% cannot be trusted without close inspection thru verify. Verify on our tools can take a long time.

Surfacingstepover

I would try another pocket type. Maybe a Parallel Spiral, or parallel spiral clean corners. See it run in verify after trying several out.

with the 3" bull you have only 2.5 inches to play with on the bottom of that for full engagement...therefore 80% of that should be 2.0 wide cut ...is that not correct?

Reverse of "Is it possible to use a drill press as a milling machine with the proper bit?". I'd think it would, but I imagine a CNC mill might be taking off less "material per unit time" than a drill press. Also, would the fluting be different for a CNC mill and drill press?

CNC stepoverCalculator

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So you say these things are "the reverse of", they are not the reverse at all. Using an end mill in a drill press is a completely different kind of operation than using a drill in a mill. An end mill in a drill press doesn't make a whole lot of sense (except in rare cases. And yes, squaring the bottom of a hole is one of them, because the end mill doesn't have to cut the center of the hole).

I think what his boss is getting at is the cutter has a width of 2.5" at the bottom. 80% of 3" is 2.4" so at 80% stepover = 2.4" the cutter should in theory clean the floors.

StepdownCNC

80% radial engagement limits your DOC considerably. Are you going for a "Waterline style rough pocket? There are some better options in the Surface High Speed toolpaths. The Area Clearance and Core Roughing toolpaths have some great options to limit radial engagement and increase your depth of cut considerably. This has the effect of maximizing your tool life because you utilize more of the flute of the cutter. What kind of tool, material, and depths are you working with?

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Meshcamstepover

Drill chucks are not mill chucks and a Jacobs taper is not a CAT taper. Drill chucks and Jacobs tapers are not designed to tolerate the radial/side force of an endmill. Thy can be pried apart as a result. Even if they aren't, the bearings in a drill press won't take the side load.

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Is there anything that can be done to acheive 80% stepover reliabley. Without excess air cuts, and or stock depth problems.

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End mills are designed to work off the ends of the tool, i.e. they are driven laterally into the work. They are built for this kind of shear stress, and not to be driven axially.

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Mills, on the other hand are designed to take all the forces of a drill press and more. A mill is a super set of a drill press so anything a drill press can do a mill can do, except for drilling unclamped workpieces (so the piece can move to allow the drill to find the center punch hole. Always use a safety stop bolted to the table to prevent workpiece spinning, especially small parts), since all mill workpieces must be fixtured.

Like I said before The CAM software I used before MC did the same thing, anything over 60% stepover would cause problems. I have been doing CAM for almost 8 years, and this kind of complaining by the machinests just drives me crazy. They wan't perfect programs, but you have to do them the way they want them, and if it causes a problem it's your fault.

Just though I'd check here before I call my reseller. I don't realy think they can do anything about this, but I have to call.

CNC stepoverpercentage

Whereas a drill in a mill makes a lot of sense. Of course you are just drilling holes, but the mill gives you unbelievable ability to position the work precisely (especially with multiple holes that need to have a relationship with each other!) that you just don't have on a drill press. You can also use the mill's auto-feed to maintain feeds correctly, and it typically has better control of speeds as well.

Stepoverand stepdownin CNC

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Carbide end mill bits are solid round milling cutters used for applications such as slotting, profiling, face milling and plunging.

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I have tried this before, and the path leaves islands of stock at anything over 70%, and runs thru them 4 or 5 steps down. My previous CAM software did the same thing.