I have been trying to improve the tool paths for the BE8108 gearbox sun gear holder. The first time, I ended up slowing things down a lot and actually took some of the initial adaptive passes in several iterations as I fixed problems, so it wasn’t clear that any one iteration would be functional from start to finish.
So, I tried it on a fresh piece of stock, with settings that I thought would resolve the pullout issues I had seen earlier. Lo and behold, what did I find but more pullout! It appeared to happen in exactly the same situations as before. The adaptive clearance would leave a thin sliver of material, then “round it off” very rapidly, resulting in a large chunk of sliver hitting the mill at once. Increasing the minimum cutting radius and tolerance helped reduce the problems some, but didn’t get rid of them entirely.
Eventually, I managed to find this thread on the Fusion 360 forum where others were having exactly the same issue. From there, I discovered there is an undocumented parameter, only available in the “Compare and Edit” screen called “Curve in Radius”. By default, it is calculated based on the tool diameter, but I found that I could add a random fudge factor of approximately 1mm to whatever the calculated version was and boom, the thin slivers were handled in a much more appropriate way and the tool never rolled over them until the sharp point was gone.
I still have more bugs to work out of this toolpath, but at least that’s one down.