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kspangler@midwestfab.com - 9/10/2019 3:57:59 PM
   
Sweep profile along centerline
I run into this ALL the time and I'm certain there is an easy way to accomplish what I need to do, or at least if there isn't then there SHOULD be:
We build gages for our parts using the model data and often need to make compound bends that must be cut from one setup in the milling center.
I can create a round that follows the centerline of the part and boolean from the block but in cases where the pass is over half the diameter of the round I need to prevent the sweep from twisting and cannot seem to get the model to complete.
For description purposes, using a CNC package as an example I can use the centerline as the toolpath and it will create the animation precisely as it follows the path but I cannot seem to determine how to create this geometry in KeyCreator. Invariably it will twist the sweep at some point so that an undercut is created in the model.
Is there a way to "lock" the alignment of the profile sweep to the top view for example so that it creates a true toolpath that follows the centerline?
In the below screenshots there is an example block and three iterations of the "end mill" showing it in various stages of the cut. As you can see there are two different faces on the block and the pass for the part that will be checked has an additional index along the bottom. This is precisely where I have the issue with this particular part. KeyCreator either gives me an error for the sweep that the profile is self intersecting or it twists the sweep to follow the centerline in a way that the end mill could not follow, as indicated by the red transparent end mill.
So is there a way to duplicate an pass cut by a vertical machining center by locking the twist of a swept profile to a top down view and if so, how?


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jason@cadcamadvantageinc.com - 9/16/2019 2:08:56 PM
   
RE:Sweep profile along centerline
I tried a few things and here is what I found.....

If I use "Rail Sweep" I can choose to use "Normal to Surface" in my "Orientation Control" settings. This doesn't work as a whole on the entire chaain though. What I had to do was use it for EACH contour of the chain individually. Yes, a pain, but it seemed to work out in the end. All my swept geometry was orientated so as to mimic a pass from the cutter. (I program too) I did have some trouble when it came to unioning all the pieces together and subtracting them from my block to create the end geometry, but after a "heal" here and a "clean geometry" there, and even a simplify now and again I was able to get some workable geometry.

It was not perfect by any means but it may be a start in the right direction since I could not find any other way to get this done.

Jason Brown
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kspangler@midwestfab.com - 9/16/2019 2:44:58 PM
   
RE:Sweep profile along centerline
Thanks Jason, Hans actually provided me with a file as well instructed me to do the same thing that you did. It's not pretty but it worked!
I hope Kubotek takes a look at this function and "fixes" it as in my opinion it is clearly broken the way it is now.

Dell Precision Tower 3620
Intel Core i7-7700 @3.60(x2)
16 GB of RAM
Nvidia Quadro M4000 (8GB)
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KeyCreator 2019 SP3 (5897) V16.3.0
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