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Now if only real world tests go as smoothly as the simulation
Like the video and this will be a great addition to the software.
Also, please include me for alpha testing.
Thanks in advance.
On 8/12/2022 5:10 PM, John Johnson
Here's a video
of a simulation I ran on a test board.
The rack file looks like this. E means end mill, T is a
step is the amount to step over in
x,y, and step_z is the amount to
step down in z.
This strategy mills from the center out at increasing depths.
Helical at the max diameter is a possibility too - for another
#tool drill_size minimum
maximum length step step_z
T01 0.015in 0.001in 0.031in 1.5in
T02 0.032in 0.032in 0.035in 1.5in
E03 0.032in 0.035in 0.124in 1.5in 0.010in
E04 0.125in 0.125in 0.375in 1.5in 0.030in
If you're interested in alpha testing, let me know. Alpha
software is not for circulation to others.
Let me know what you think of the video.
On 8/10/22 2:45 PM, John Johnson
I've been thinking about and working on the long-requested
(ca. 2018) feature that would let one mill holes of different
diameters using an endmill.
I would like your input.
- Is this useful?
- Do let me know if you have suggestions on gcode. My
knowledge on this is limited. I would like to support as
many controllers as possible (TurboCNC (happy to see
TCNC is still around!), Mach3,
etc.), so make it as generic as possible.
- I'm thinking G03 (counter clockwise) for all holes.
- From what I've read, using IJ is preferable over R, and
I recall from my experience R arcs can get whacky.
- I'm thinking 4x 90° arcs to make a circle. Again, to
accommodate as many controllers as possible.
- I'm concerned about holes that are larger than 2x the tool
- For example, in the image attached, the tool is
0.015"/0.381mm and the holes are 0.020"/0.508mm,
0.035"/0.889mm, and 0.050"/1.27mm. There is a
0.005"/0.127mm post in the center hole, and 0.020"/0.508mm
on the right-hand hole.
- The debris left in the center (see attached pics),
which could potentially become ensnared by and break the
- One way to eliminate this is as two (or more) holes, a
smaller one to full depth, then larger ones.
- This would probably need "pecking."
- I could also use a sort-of center-out strategy, where
the cutter starts in the center, then mills at
increasingly larger diameters until the desired size is
reached. Rather than the helical path shown, I would
probably just plunge some amount in the center, then start
milling the concentric circles at that depth out to the
max diameter, plunge at the center a bit deeper, rinse and
- How do we control chip load?
- Step down for Z axis as an absolute amount (e.g.
0.25mm/0.010") per pass?
- What about increasing the diameter if concentric holes
or multiple passes are used?
- Could be a fixed maximum, I suppose, or some
percentage of the tool diameter.
- Code that generated the images is attached.
- Let me know what you think about it too. I just
generated it in Excel for the time being.
Would appreciate your input and expertise!