- May 31, 2011
- upstate nj
I assume you are making rectangles with a constant radius on the corners...is that correct?
Also, you are keeping the males and throwing away the frame with the female cutouts??
If that is the case, a couple of thoughts spring immediately to mind.
First, others have posted about the desirability of wire cutting the center holes if you want them dead nuts, and they have also posted about the uncertainty around wire pickups.
As was pointed out...it takes very little in the way of dirt or burrs or shaved wire to make a bad pickup and you can really chase your tail trying to get confidence all is as good as it can be.
When every successive pickup is different by a tenth or two it gets hard to know where you really are.
So wiring the hole as well as the outside is an obvious way to eliminate the hassle and uncertainty of wiring to a finished feature...it allows you to make the parts as accurately as the machine is capable of.
The second point is about the code:
Some of you have commented on the length and ugliness of it.
I suspect the part is being programmed without a taper command, but by breaking up the radii into small linear moves in order to get an equal radius top and bottom.
If you just tip the wire over with a taper command and run G02 or G03 in the corners, you won't get a constant radius.
All the CAM software I've tried defaults to small G01 moves and UV displacement commands to manage constant radius tapers, so the code gets huge, and if you look at what has been posted here, that's the pattern that's emerging.
There is another way called "Complex Upper and Lower" in which you stitch the code for the upper profile together with the code for the lower profile, line by line with colons in between.
It will use G02 or G03 for arc moves, and you can use it to make all kinds of weird shapes, including constant radius tapers.
I know of no CAM program that can output this kind of code, so whenever I want to do it, I have to generate the code for the upper path, do the same for the lower path and then put them together manually...a royal PITA but it gives very compact code that's easy to edit.
On a last note, I concur with everyone who's pointing to a setup or basic programming error to account for your unwanted outcome.
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Jeeze Marcus I was getting worried!