I have the 50W router, and have a project in mind that I want to use this on.
My test piece is just some rubbish pine, but I would like to attempt to put rounded edges around the top of the material, and cut a 5mm curved slot about 10mm deep.
I can put the slot in using luban if I wanted to, I can draw that up no issues in fusion360. I have done a complete drawing, and have been trying to work out the best bits to create the desired outcome. I was curious if creating the rounded edges would be easier in the rotary module, once I can work out how to set that up in Fusion. I only have the original set of bits that came with the machine.
I was assuming the 4mm end mill to create the basic shape I want, and then potentially the ball nose to finish it off. Or should my curved slot be done using the ball nose?
What you describe is IMHO a standard thing, not too complicated. Fusion 360 has a lot of milling strategies, one of them slot cutting, another pocket cutting, which might be exactly what you need. These strategies do not require the rotary, and adding the rotary to the equation opens up a can of worms - if you can avoid it, do not use it. Regarding the bit to be used: I only feel slightly entitled to give recommendations here, being a beginner myself, but from what I learned you use the flat end mill for roughing and sharp edges, while the ball end mill is used for smoothed, rounded edges and good surfaces. Obviously, at the bottom of a slot, the shape of the mill defines how the edges look like, at the top of the slot your model defines it, and the tool will make it smoother (ball end) or sharper (flat end).
this is the basic idea. I am working on it still, but this is my test piece. I’ve followed the instructions i’ve found elsewhere on here. I’m hoping it works. So i’ve done it as a pocket, and using the ball nose. it’s just a roughing cut i suppose. It will all depend on if I want the bottom of the slot to be perfectly flush
A few thoughts (take with a grain of salt, would not consider myself an expert): The ball end mill is more thought for the finishing pass - I’d consider doing a roughing pass with a flat end mill first, and then a surface finishing with the ball end mill. And: I assume that you have modeled the stock piece and just want to round the edges? If not, if it is a larger piece, the vertical edges might be a problem, digging into a lot of material. If it is your existing stock, then I’d consider to just cut the slot and round the edges with classical sanding paper - much quicker
Well the ball nose worked, even achieved the rounded edges across the top, but wasn’t as clean as I’d like, but I was using crap wood, and wasn’t spot on with all my measuring, so end result was good for the effort i put in. For my actual plan, I was going to use thinner material. If I did so, I was wondering if I could actually cut out my desired shape from a solid, then it would round the outside edges also, but I’d be worried about the cutter as it got deep with it cutting on both sides. The slot at least has space, so each pass it cutting the bottom of the slot and a side.
I wouldn’t bother CNC cutting the block out of a bigger block - there are easier ways to do that. Start with a block the correct finished size, you would have to set up your X and Y datums first though (not forgetting to add half the diameter of the cutter). Even then, the position of the slot does not need to be so accurate.
I’ve used CNC milling to cut out smaller shapes from a larger block. Boxkite is right: For simple shapes it might be easier to cut them with “classical” methods, i.e. a saw or so, but more complicated shapes are better with CNC milling IMHO. The relevant thing is that your milling bit has the necessary cutting depth. I had a few fights with Fusion to really cut out something from a larger block - Fusion seems to always try to mill away all excess material - I only wanted to mill away the circumference of the workpiece… I’d recommend to closely incpect the toolpaths before running them. Also, make sure that the workpiece is fixed properly at all times - you must not forget that when you’ve cut out your piece from a larger block, it is free to move unless it is somwhere fixed, and this may cause havoc. Fusion has for cutting out things functions to leave small bridges that keep the parts connected, which later can be easily removed youst using a knife.
