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Originally Posted by apples000
We have no idea where to start with generating the g-code with this in MasterCAM. Has anybody found a way to do this, or are we better off writing the gcode ourselves?
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Gearotic is awesome software for gear design. It can also generate g-code, but I believe will do so only for 2d or 2.5d type work. That limits it's built in CAM usefulness to fairly large gears (unless you're willing to run a very small cutter).
Running the fourth axis and gear cutting tool profile should be possible using mastercam, however a generic post file may or may not handle it well. Check to see if Tormach has any guidance on this. As for the specific steps involved in getting the right operations set up in mastercam take a look at youtube. If you happened to have bought Sprutcam along with the mill check that out too; it's actually pretty capable for 4th axis work.
Quote:
Originally Posted by apples000
Our second question deals with the actual cutting. We've found that with our CNC machine (it's a Tormach) some of the more aggressive cuts that work just fine on our bridgeport result in a lot of screeching from the whole machine just warping and being sloppy.
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As to the performance of the Tormach: it doesn't cut like a larger mill because it's not a larger mill. Mass helps smooth a mill out a lot (though smoothness is not necessarily an indication that the cut parameters are good!). You may need to better match your expectations for cut speed with the size of the machine. Rigidity in machine tools is a complicated thing. In my experience with a series 3 1100 machine rigidity is rarely ever a factor. Things like spindle power and tooling are almost always the limiting factors.
How are you calculating your feeds and speeds?