Last week I posted about this problem I was having with aluminum. Basically my OD’s were small and my ID’s were big and the slot radii were slightly out of round. I was going to do some more testing on aluminum but I ran out of actual ideas for things I need/want to make for now so I decided I would retry carbon fiber with my mister to keep the dust down (which works btw!) A few months back I designed my own frame for a drone, and was going to have somebody else cut it; didn’t end up working out. Fast forward to me building an MPCNC, It’s been close to a month since I’ve flown my drones and I wanted to cut/build/fly my design finally. When I designed it I 3D printed it out before finalizing it (so my drawing is very slightly different now then what it used to be, hence the small dip on the inside end of the cf part). The 3D prints were purposely cut rough but are still very close.
I cut an aluminum part that looked very close to my numbers with trochoidal cutting, but with these CF parts that’s not an option due to the size of the slots, holes, ID’s, etc. I’m currently using one of the diamond cutter endmills, 3/32" in diameter. But it was the same deal with different 1/8" endmills on aluminum also. Also obviously tried different speeds and DoCs, with no avail. The cf pictured is the most recent one I cut, and that was a full DoC (4mm) at 200mm/m and it wasn’t struggling at all, not sound wise at least. Belts are nice and snug, random but thought I’d include it. Verified tool size in Estlcam and double checked it with calipers also.
One thing I thought was maybe the acceleration speed I set up with Estlcam was too fast. It was set to reach max speed after 2mm of distance. WAY upped it to hit full speed at 32mm. Didn’t help. I thought that maybe the inertia was set incorrectly at the default 85% but then reconsidered that thought when the OD is cutting smoothly (while still undersized lol).
My last thought is that something is going wrong in Estlcam’s gcode generation. If anyone knows how to read it and find any errors, I can provide a .dxf of this part and the gcode file for checking out. I would’ve tried camming it in Fusion, but I need to learn more about the cam side of it, I’ve been putting it off…