The .055 stepdowns are the problem here with this particular tool path. You will find that the tool path struggles to make sense of the .055 step-downs where none are possible so you get these weird sewing machine vertical moves as a result. These can by the way show up in your finish and can be a problem. When you are cutting and removing metal fast you generate deflection and these little jaggies do not have that problems. The end result is they will cut past the roughing cut surface. So you either remove the sewing machine by eliminating them or do a finish profile or ramp down cut to remove the extra material you have left for this purpose. As a rule I always leave a little for finishing now and don’t rely on Adaptive to do this.
Perhaps this is a bad habit of mine but with ZW3D and CW4SE and HSM I tend to find that the 3D strategies seem to deal with the part structures better and so most of the time even though the cut is technically a 2D cut I opt for the 3D.
So what exactly do you fellow users do in similar situations? Please remember that I do not represent myself as an expert. What I am is a guy who has his own shop and does his own design, fabrication and machining. This quite often does not leave a whole lot of time for experimentation and sometimes information on how to best do things is elusive especially when there are no comprehensive user manuals.(cough cough hint hint HSM) . What I also am is someone who seeks better answers from those who also cut and part of the reason I post is that I hope others will chime in with what they do and why. Besides talking about what is going on with CAM and CAD programs I also want to post information on how to do these things. All of you look for answers but very few are willing to speak up about what they do and why. Perhaps you might reconsider and share some things here. This Blog is open to you and also to worthwhile links to your material if you have some we should know about.
He references being able to do this in one toolpath in CAMWorks and you can do the same in HSM with the bore cycle. Read the comments for why I chose two tool paths on this hole. One of the premises of Adaptive or Volumill type toolpaths is the ability to use full flute length thus increasing the amount of metal removed per tool over it’s usable life. I could have easily cut this with one step down to full depth rather than two. I neglected to show this in the tool path as an oversight not because I will be cutting it this way in production.