Thread: Tool Offsets - What's wrong with this Gear?

**edo** · 12-27-2006, 06:24 PM

I took a gear drawing from AutoCAD and used KCAM to convert to G-Code. The first cut looked good, but the teeth were pretty small - I forgot to account for the tool offset. I added G41 D1 and set up Tool 1 in Mach3 as the 1/8" bit that I'm using.

The tops of the teeth came out correctly, but there's a strange undercut in the corners at the bottom of the teeth and there's a peak where it should be flat between these corners. In the picture, the gear in the back is the first one I cut with no offset and the one in the front was what I got when used G41. You can see the space at the base of the teeth and the little spline in the middle.

**HuFlungDung** · 12-27-2006, 08:18 PM

What is wrong? It's undercut

I suspect it is a case of tool interference due to inproper offset of the path within the controller's rad comp routine.

The best way I've found to fix a troublesome path for radius comp is to fillet the internal corners of the 2d curve to match the tool radius. If the controller could execute the original path correctly, this is exactly what you will get anyways.

So where the tooth meets the root circle, fillet the geometry to your 1/16" radius. You might discover that you will have to do some manual trimming to get a good continuous curve.

Then, redo the toolpath on this new geometry.

**edo** · 12-28-2006, 05:40 AM

Thanks, Hu. I'll play with it some more and see what I can do with it. I'm new to all this and was foolish to think it would be as simple as putting a G41 in the code.

**crob09** · 09-20-2012, 04:45 AM

Originally Posted by edo

I took a gear drawing from AutoCAD and used KCAM to convert to G-Code. The first cut looked good, but the teeth were pretty small - I forgot to account for the tool offset. I added G41 D1 and set up Tool 1 in Mach3 as the 1/8" bit that I'm using.

The tops of the teeth came out correctly, but there's a strange undercut in the corners at the bottom of the teeth and there's a peak where it should be flat between these corners. In the picture, the gear in the back is the first one I cut with no offset and the one in the front was what I got when used G41. You can see the space at the base of the teeth and the little spline in the middle.

Just wondering if you could help me, how did you get the offset on the second gear? How did you set it up, in Mach3 or Lazycam?

Thanks,
Rob

**edo** · 09-20-2012, 05:27 AM

Rob - you got me scratchin' my head - that was almost 6 years ago. I believe I took Hu's advice and used a fillet in the drawing before converting to G-code. I guess it didn't even occur to me that space between the teeth couldn't be smaller the cutting tool. I may have went to a 1/16" bit too.
Good luck.

**crob09** · 09-20-2012, 04:32 PM

Originally Posted by edo

Rob - you got me scratchin' my head - that was almost 6 years ago. I believe I took Hu's advice and used a fillet in the drawing before converting to G-code. I guess it didn't even occur to me that space between the teeth couldn't be smaller the cutting tool. I may have went to a 1/16" bit too.
Good luck.

Hi,
I tried a smaller bit but still no luck, but thanks for the suggestion and thanks for thinking about the question.
How do I use Hu`s advice and add a fillet? I am using Solidworks dwg editor and Mach3 with Lazycam, I don't have a good CAM program and don't have the money at the moment.
Do you think ReplicatorG or Pronterface would work in place?

**edo** · 09-21-2012, 02:43 AM

I use TurboCad and DesignCad 3D, both relatively simple & inexpensive and they work for everything I've needed. Solidworks dwg editor has the fillet function. Fillet turns a point where two lines meet into a curved line. Since we can't cut a sharp inside angle with a round bit, we fillet the intersection to match the radius of the bit. In DesignCad, I just hit F and a pop-up lets me enter the radius; then I click on one of the lines, move the cursor to the other line, click again and it turns the intersection into a curve.
Hope this helps.

**sinha_nsit** · 09-23-2012, 07:27 PM

Possibly the problem is with too large tool dia for the gear being cut.

**crob09** · 09-23-2012, 09:59 PM

Originally Posted by sinha_nsit

Possibly the problem is with too large tool dia for the gear being cut.

Hi, Actually that's what I want the offset for, I need the software to produce G-code with that consideration.

**sinha_nsit** · 09-24-2012, 03:31 AM

If a software being used, a larger step length might help.

**crob09** · 09-24-2012, 05:03 AM

Originally Posted by sinha_nsit

If a software being used, a larger step length might help.

How?
i am using Mach3 as machine software

**Superman** · 09-24-2012, 09:53 AM

Offset the teeth profile by 1/2 of the tool diameter you want to use, this offset contour is what you want to put thru KCAM to get G code. Your offset setting (D1) in Mach3 is set to zero.

To get deeper into the root radius of the tooth, you would need to use a smaller tool, so offset the tooth profle for the area you want this smaller tool to go, by the (small) tool radius, & output that new contour thru KCAM

You can add the G41 D1 to the start of each cut...and G40 at the end, you shouldn't need it if your tool is cutting correct size, ---- a minus tool offset in D1 ( in the control ) makes the tool cut closer to your part.

place a circle ( T1 diameter ) on the V (1st toolpath ) to represent where the first tool can get to, showing you where to start the 2nd toolpath from.

**crob09** · 09-24-2012, 05:09 PM

Originally Posted by Superman

Offset the teeth profile by 1/2 of the tool diameter you want to use, this offset contour is what you want to put thru KCAM to get G code. Your offset setting (D1) in Mach3 is set to zero.

To get deeper into the root radius of the tooth, you would need to use a smaller tool, so offset the tooth profle for the area you want this smaller tool to go, by the (small) tool radius, & output that new contour thru KCAM

You can add the G41 D1 to the start of each cut...and G40 at the end, you shouldn't need it if your tool is cutting correct size, ---- a minus tool offset in D1 ( in the control ) makes the tool cut closer to your part.

place a circle ( T1 diameter ) on the V (1st toolpath ) to represent where the first tool can get to, showing you where to start the 2nd toolpath from.

How do you use the G41 command?
I have tried a few different kinds of CAM software and because I am new to each one I am struggling. How do i change the G-code if I want to use a 1/8"bit?

here is the G-code, how should it look with the G41 command added to it?

N5 (File Name = large gear on Monday, September 24, 2012)
N10 (Default Mill Post)
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N2495 X8.5450 Y59.9096
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N24085 Y128.1744
N24090 Y128.2692
N24095 Y128.3643
N24100 X136.4347
N24105 G0 Z1.0000
N24110 X137.7636 Y129.5984
N24115 Z0.0000
N24120 G1 X136.4347 Y128.3643
N24125 G0 Z1.0000
N24130 X139.7575 Y133.1115
N24135 Z0.0000
N24140 G1 X139.6628 Y132.6367
N24145 X139.4728 Y132.1621
N24150 X139.3777 Y131.7821
N24155 X139.1880 Y131.4024
N24160 X138.9980 Y131.0226
N24165 X138.7132 Y130.7379
N24170 X138.2384 Y130.1682
N24175 X137.9537 Y129.8833
N24180 X137.7636 Y129.5984
N24185 G0 Z1.0000
N24190 X139.7575 Y133.1115
N24195 Z0.0000
N24200 G1 X139.6628 Y133.2063
N24205 X138.9980 Y133.9658
N24210 X138.6182 Y133.8710
N24215 X138.1434 Y133.7760
N24220 X137.2892 Y133.4912
N24225 X136.9095 Y133.3014
N24230 X136.5297 Y133.1115
N24235 X136.2446 Y132.9216
N24240 X135.8648 Y132.7315
N24245 X135.5801 Y132.5418
N24250 X135.2954 Y132.2569
N24255 X133.9660 Y131.0226
N24260 G0 Z1.0000
N24265 X133.6813 Y131.1176
N24270 Z0.0000
N24275 G1 Y131.0226
N24280 X133.8710
N24285 X133.9660
N24290 G0 Z1.0000
N24295 X133.6813 Y131.1176
N24300 Z0.0000
N24305 G1 X132.9218 Y131.7821
N24310 X132.3520 Y132.4468
N24315 X131.6875 Y133.1115
N24320 X131.0226 Y133.6811
N24325 Y133.7760
N24330 Y133.9658
N24335 Y134.0609
N24340 G0 Z1.0000
N24345 X132.2569 Y135.3900
N24350 Z0.0000
N24355 G1 X131.0226 Y134.0609
N24360 G0 Z1.0000
N24365 X133.8710 Y138.9980
N24370 Z0.0000
N24375 G1 Y138.6182
N24380 X133.7764 Y138.1434
N24385 X133.5863 Y137.7636
N24390 X133.4912 Y137.2890
N24395 X133.3016 Y136.9093
N24400 X133.1115 Y136.6244
N24405 X132.9218 Y136.2446
N24410 X132.7317 Y135.9597
N24415 X132.2569 Y135.3900
N24420 G0 Z1.0000
N24425 X133.8710 Y138.9980
N24430 Z0.0000
N24435 G1 X133.7764 Y139.1878
N24440 X133.0164 Y139.7575
N24445 X132.6367 Y139.6626
N24450 X132.1623 Y139.5676
N24455 X131.7825 Y139.3777
N24460 X131.4028 Y139.1878
N24465 X131.0226 Y138.9980
N24470 X130.7379 Y138.7130
N24475 X130.3581 Y138.5232
N24480 X130.0734 Y138.2384
N24485 X129.7887 Y138.0486
N24490 X129.5986 Y137.7636
N24495 X128.3643 Y136.4345
N24500 G0 Z1.0000
N24505 X128.0796
N24510 Z0.0000
N24515 G1 X128.1746 Y136.3394
N24520 X128.2692
N24525 Y136.4345
N24530 X128.3643
N24535 G0 Z1.0000
N24540 X128.0796
N24545 Z0.0000
N24550 G1 X127.9845 Y136.5293
N24555 X127.2250 Y137.0990
N24560 X126.5605 Y137.6688
N24565 X125.8956 Y138.2384
N24570 X125.1361 Y138.8081
N24575 X125.0415 Y138.9029
N24580 Y138.9980
N24585 X125.1361 Y139.0928
N24590 G0 Z1.0000
N24595 X126.1808 Y140.5170
N24600 Z0.0000
N24605 G1 X125.1361 Y139.0928
N24610 G0 Z1.0000
N24615 X127.4151 Y144.3148
N24620 Z0.0000
N24625 G1 Y143.9350
N24630 Y143.4602
N24635 X127.3200 Y142.9856
N24640 X127.1300 Y142.6059
N24645 X127.0353 Y142.2259
N24650 X126.9403 Y141.8462
N24655 X126.7502 Y141.4664
N24660 X126.5605 Y141.1817
N24665 X126.3704 Y140.8019
N24670 X126.1808 Y140.5170
N24675 G0 Z1.0000
N24680 X127.4151 Y144.3148
N24685 Z0.0000
N24690 G1 X127.2250 Y144.4098
N24695 X126.4655 Y144.9795
N24700 X126.0857 Y144.8844
N24705 X125.7060 Y144.6946
N24710 X125.2312 Y144.4098
N24715 X124.8514 Y144.2198
N24720 X124.5667 Y144.0301
N24725 X124.2820 Y143.7452
N24730 X123.9968 Y143.4602
N24735 X123.2373 Y142.6059
N24740 G40
N24745 X122.1931 Y141.1817
N24750 G0 Z1.0000
N24755 X120.4840 Y148.9670
N24760 G1 Z0.0000
N24765 G42
N24770 Y148.0176
N24775 X120.3889 Y147.1632
N24780 X120.1042 Y146.0237
N24785 X119.9145 Y145.6440
N24790 G40
N24795 X119.6294 Y144.9795
N24800 G0 Z1.0000
N24805 M5
N24810 M30

**Superman** · 09-25-2012, 03:46 PM

Rob

Cutter comp usage can be quite tricky at times, so don't expect to be an expert after your first sucess, each toolpath you create can have it's own little series of glitches

comp basics ( also refer to the manuals for the machine controller )
-comp is started with the tool away from the part, the first move is typically along a line ( many controls cannot start comp on an arc- rule #1 )
- comp is cancelled by a G40, ( by itself, or it can be with an X/Y move, - not along an arc ), you should have the tool move away from the part before cancelling
- decide on which side ( of the profile ) you want the tool to travel, and in what direction ( ie take a circle, tool to be on the outside, travelling clockwise ), this dictates what G code to use from the G41/G42 choices
- G41 means tool is travelling on the left side of the contour ( climb milling ), if on the outside it is a CW motion, if inside, it will be a CCW movement
- G42 means tool is travelling on the right side of the contour ( conventional milling ), if on the outside it is a CCW motion, if inside, it will be a CW movement, you have to define the chaining direction carefully, and apply the correct G comp code.
- never start comp on an inside corner ( ie inside a square pocket )
- G41/G42 require a D word that holds the offset number ( ie G41 D1 , where D1 has the cutter radius value to adjust the toolpath )
- there are various methods of programming the toolpath,
----- using the part's shape--- where the cutter radius is input into D1, & any internal radius on the part shape, cannot be smaller that the tool radius value in D1
----- using a contour that is already offset ( from the part shape ) by the tool radius & then used as the toolpath, then D1 is then set to zero,

To adjust the toolpath on these strategies, if the D value is increased , then the toolpath is further away from the part shape. If D is decreased, then the part shape is made smaller

NEVER mix these two stategies together for the same tool in the same program.

the 1st strategy is the old method, or if no CAM system is used, when the comp is applied, the actual path that the tool follows is the path that is used in the 2nd strategy....

It is best to understand which one ( CAD or machine control ) is doing the calculations to get the toolpath to make the correct size part

Code:

N5 (File Name = large gear on Monday, September 24, 2012)
N10 (Default Mill Post)
N15 G91.1
N20 G0 Z1.0000 
N25 M3 
N30 X17.3749 Y36.7433 
N35 G1 Z0.0000 F60.00 
N40 G42 D1 <--- go & lookup the offset value ( sometimes only needed on the first use )
N45 X16.8051 Y36.2685 
N50 X16.2354 Y35.6988 
N55 X15.9507 Y35.4141 
N60 X15.7608 Y35.0342 
N65 X15.4759 Y34.6544 
N70 X15.2860 Y34.2746 
N75 G40

- You are conventional milling on the right side of the contour, if the path is the actual finished shape, and the profile is chaining CW, then you have stuffed the part. But if your chain is CCW, then 1/2 the battle is done....but the N30 line is actually on the part profile, your descend point will also stuff the part. you are not starting the comp away from the shape by at least the tool radius.

- if your profile is the 2nd strategy, & as the D1 value is zero, there is no adjustments to be made, so the G41/G42 is not really required. comp is only necessary to finely adjust the toolpath to get finish size- this is when you may need to have thoes codes inserted in your program.

I have only touched on the basic concepts, there is a lot more info to be taken in
- read up on how comp is
--- adjusted on internal shapes
--- going around sharp external corners
--- how many NC lines ahead (look ahead or buffer ), that the controller looks to plan the next series of moves. You do have lots of short moves when approaching the root radius of the teeth, so it can't see what is supposed to happen on the upside of the adjacent tooth ( this is where it is undercut ). But if the lines were replaced with longer arcs, it may be able to follow the shape better.

Try having AutoCAD generate the tooth form using a series of arcs instead of many segmented lines, you will also notice your programs will be much shorter.

I hope this has not made you more confused than what you already are ?...LOL

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