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Jamey Saldana

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Aug 2, 2024, 8:16:39 PM8/2/24

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I'm trying to machine the inner surface of the cylindrical workpiece, shown in the picture. The workpiece is a converted step file from a originally stl file of a 3D scan. It has no thickness and includes only triangular mesh elements. So it isn't possible to select a inner and outer surface of a triangular element. It's only possible to select the whole triangular element.

In Mastercam 2022, you can view and flip the surface normal direction of mesh entities, so that would make this a simple fix. In 2021, I'm not actually sure if there's any way to even view mesh normals. There are a few different ways we could still work around this and force the machining from the backside. If you can upload a file, I could provide an example.

A simple "parallel" or "Morph" would give you control over "how the tool moves across the "drive surface", and then you can use the "Retract Tool, Along Tool Axis" Collision Control, to keep the tool tangent to the Mesh, instead of the cylinder.

There is only one triangular mesh element with no thickness, imported as a step file. There is only the option in Mastercam 2021 to select the whole element, when I choose a mill machine and the multiaxis parallel toolpath.

"In Mastercam 2022, you can view and flip the surface normal direction of mesh entities, so that would make this a simple fix. In 2021, I'm not actually sure if there's any way to even view mesh normals."

I would guess that Mastercam assigns a "global normal direction" to a Mesh Entity. I say this because I haven't seen an option to "view or flip" the normal direction of an individual facet (triangle).

Mastercam has added new capabilities for machining Mesh geometry, especially the last 4 releases of Mastercam. That said; you are still much better off using Surface or Solid geometry. Mesh entities do not contain any "curvature data". The quality is limited by the size of the facets used to "mesh" the model. This is essentially a 'static tolerance'. Yes, there are now some tools for re-meshing and smoothing an existing Mesh, but it will never be as clean as working directly with Surface data.

In the beginning of the sequence, the mill tool is in the correct plane (Left). But when the mill starts to machine the part, Mastercam is machine the wrong plane (Right). I added the Mastercam 2021 file and the part in the annex to make my problem more clear.

The start move in backplot is and seems always be part of Mastercam for every version is wrong. Unless the model and toolpath are at TOP/TOP/TOP you will alway see this false start. In 5 Axis machining I always teach customers to ignore that 1st move and watch the rest of the motion. Mastercam is not kinematic aware as a software it is World aware as a software. Since the kinematics of the machine are not part of the core system then the backplot is not aware either. It needs a point of reference to start and since it is written from a World TOP method for all calculations then that is where it needs to make it's reference from. Post the code and see what they code tells you then you will see what I am explaining to you here. Your main WCS is right, but your C-T Plane is left so move the STL to top and set your planes to top and backplot again and you will see the problem go away.

How do I tell the tool that I want the circle around the X axis, not the Y axis? Extremely frustrating. The tool always wants to lay the object down. OK for a sheet of plywood, but not ok for a circle that is being used as a path for the follow me tool. AHHHHHHH!

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I have just recently set-up the Prusa XL with the 5 tool heads last week. The setup went smoothly however the printer has been failing the z-axis test and tool offset calibration tests. The z-axis test had failed several times and then all of a sudden the test passed without me making any adjustments to the printer. After re-running the test it has randomly failed and passed numerous times and I've not been able to identify what is allowing it to pass or causing it to fail - the test gives no information, just pass or fail.

The tool offset calibration has yet to pass after multiple attempts. The calibration fails during the first tool calibration and I have swapped over the extruder head so that the calibration starts by using a different extruder to check if it was a problem with the extruder but the test still failed at the exact same spot as all prior tests. I have also re-run all prior calibrations which have all passed but when it comes to the tool offset calibration it has always failed in the same spot and comes up with the error message attached.

I faced a similar problem and spent a month troubleshooting it with tech support. Ultimately, it was discovered that the core XY was not locked in place properly. The Z-axis extrusion pins need to be properly locked in place in the holes in the base and the core XY. It would seem obvious, but the pins can shift slightly out of their holes when being assembled and still be tightened down. It was a stupid mistake on my part, but was obvious when I reassembled the printer. Works like a champ now. Super pleased with the print quality. Note of caution: put the Z-axis bearing stops in before disassembly to avoid losing bearings.

Thanks for your response. I have just noticed a notable gap between the top of the z-axis extrusion and the core XY frame. I have attached some images, would you be able to say if this looked similar to what you had seen on your printer? Just before I begin disassembling. Also, do I need to disassemble the back plate and extruders before I try take off then re-attach the core XY, or can I just undo whatever is holding down the core XY and re-jig it to remove the gap and then fasten down again?

Good gracious, that's not right. The surfaces should have zero gap and torqued together tightly. The bump on the vertical extrusion should be entirely within the groove of the horizontal extrusion. It's a tight fit and you need to "wiggle it" together before torquing down the bolts.

I had to disassemble most of the printer, especially the back/side plates and the cabling, to maneuver the core XY. I took off the toolheads from their pegs and disconnected the cables. It will probably depend on your workspace and whether you have a second set of hands to help. I decided to take most of it apart and organize the parts/fasteners in small bags to keep everything organized to go back together. It's a pain, but it's worth it in the end. Good luck!

Thank you for the responses @mikeo-2 & @nhand42. I was able to disassemble the side enclosure panels and both electronics covers on the back plate. This was all that was needed to access the screws to free up the core XY. From here I re-jigged the core XY to fit better on the pins, at this point there was still a gap between vertical extrusions and core XY extrusions. Upon torquing up the screws this gap was closed.