In this lesson, we'll be roughing and finishing a closed pocket. After completing this lesson, you'll be able to; create a sketch to define the closed contour, and analyze an adaptive versus a traditional pocket operation. Let's carry on with the file from our previous example, and let's talk about roughing and finishing the internal pockets. So you'll notice as I hover the cursor over and take a look at the faces that are highlighted that these are actually one big pocket because there's a small opening that goes between them. However, when we talk about strategies for cutting these areas, we're not going to be cutting them as a single pocket. We have a couple pads in the corners for circuit board or some other equipment table tool and we really can't just take a large tool in and clear this out and manage to go through this small section. So we need to understand some of our options we have when we're clearing out this geometry. We already know that we can use options like 2D adaptive clearing, we can use them 3D adaptive clearing as well, but we also have our 2D pocket tool path that we want to talk about and explore. So let's go ahead and let's start with our 2D pocket and take a look and see if it is a valid option here. We're going to continue to use tool number 10 or half inch flat end mill, and for our pockets selection, notice that it's automatically trying to grab the entire thing. If we try to select a smaller region, you can see that it's grabbing everything here and we're not able to close this off. If we manually move our way around and we try to select an Open pocket, let's go ahead and grab all the way over to here and we hit the plus sign, it still grabs the entire thing. So what we need to do in this case is expand our model, expand the pad, expand our sketches, and we want to find sketch 2. Sketch 2 will contain sketch geometry that'll allow us to select the sketch that was used to create this geometry before that small opening in the wall was there. So if we didn't have this, we could also go back to the model workspace with the design workspace depending on which UI preview you're using and we could actually create that sketch. Now, this pad was designed in fusion so thankfully we already have that information available. But notice that this contours selected at the top of our pads so we will have to make sure we select the appropriate depth for it. Let's go ahead and hide the sketch and compress the model view. Then we want to go into our passes section. Make sure that all of our settings are okay, we're leaving stock and that's going to be okay and everything else in here looks okay. We're not going to do any finishing passes just yet. So then let's deal with our heights. Right now, the height is based on the selected contour but I want to make a selection and I'm going to put it down at the top of this pad. The reason I want to do that is because I need to come back in, and a need to finish that other area because I'll be finishing both the floor and the walls. So we're going to have to come back in and do a few things. We'll need to come in and finish the walls at the bottom, we'll need to come back and finish the walls on these corners above this with a contour operation and some lead in and lead outs, and will need to make sure that we do this without taking too deep of a cut and risking any deformation in the wall. So with those options set and the default linking parameters and the default passes, let's go ahead and go back to a top view, go back to our geometry and take a look at this view from the top down. We've talked about this before whenever we're selecting contours. We need the arrow to be on the side that we're actually cutting. So as we look at this view, there's a few things that I noticed. One, the shaded blue section outside of our contour is on the wrong side, it's not representing the pocket that we're trying to cut. What it's actually doing is, it's taking the stock view, the original stock in the outside of our contour. Also the red arrow is not in the right side. So we're going to left-click on that and notice how our preview changes, and now it shows that arrow on the inside and the highlighted section on the inside as well. I'll navigate back to a home view and then I'll say okay. So now we have a pocket operation that comes down and makes that big cut and removes a lot of material from the inside. However, because we didn't adjust any of our settings, we have to go back in and turn on multiple steps. So we're going to use our depth cuts using the multiple depth option, and we're going to allow it to go down a certain amount, in this case, maybe a quarter inch at a time. Going down a quarter inch at a time will be half of our tool, and this is generally going to be the max that you want to do with a traditional toolpath. So we're going to say okay, and now we're going down in a couple different steps in order to get that raw material removed. Notice that this does produce a warning for us. Again, we've got some lifting issues that are happening. Now, I know because we want to keep a consistent wall thickness, that this is not going to be the best option because of the way that the tool is going to come into this pocket. If we select setup one and we simulate this, we'll start past the first operation and then we'll start to play the second operation. If we take a look at the way the material is removed, it's doing one big helical entry then it's moving over and taking a lot of material out from the side. Now, this might be okay depending on what you're cutting, but as it engages at material close to the wall, we are going to see some deformation. The tool is going to be pushing so hard into a lot of material that we're going to start to see some of that deflection and ultimately, it could potentially create an issue where the outside and the inside aren't parallel. In order to get around that, I'm going to use my adaptive tool paths. Now, I can't change this tool path, so I'm going to delete it then go into 2D and select adaptive clearing. We'll be using the same tool, tool 10. For geometry again, we want to show our sketches, we're going to show sketch 2, and we're going to select this contour making sure that the arrow is on the correct side, then we're going to go into our heights and for the bottom, we're going to use a selection option. We want to make sure that we select either appoint, an edge, or a face. You'll notice that it's not allowing me to select anything here, but if I hold down the left mouse button, you'll notice that I have the option to grab that face. So far, that looks pretty good. Under our past two section, we can use multiple depths if needed but I'm going to allow it to cut the entire thing in one depth because now, we're keeping a consistent load on the tool, we're not going to be engaging a lot of material. We can utilize this tool, and we're going to go ahead and say okay, and take a look at the tool path. Now, if we simulate this again, again we'll step past the first operation and we'll take a look at the second. We're still doing that helical entry just like we were before in the middle of the pad, but as soon as it gets to the final depth, it starts to move over and smaller amounts. So what this is going to do is, it's going to allow us to keep that consistent load on the pad. When it goes into those corners, it's taking a much smaller load. If we're worried about deflection, we can also go back into our adaptive tool path, go back into passes and we can reduce the load. For example, instead of making it 0.2, we can make it 0.12. This will allow it to take smaller cuts each time and reduce the amount of load on the pad that we're trying to cut. So now, if we go back into Simulate this, will step past that first operation and we'll take a look at the second operation that helical entry and now it's taking a smaller cut each time, pushing against the stock, pushing against the material less, which means that we're going to get less deflection. So everything looks pretty good here and obviously we're not done, we need to step down one more time. In order to step down one more time however, we have a problem because we no longer have a sketch that allows us to do that. If we expand the model again, and we take a look at the sketches we have, there's a sketch at the bottom here, the sketches at the top, but it doesn't contain those pads. We have a sketch here that shows the removal of that, and again it doesn't contain those pads in the corner. We have this sketch here, which does contain the pads however, they don't have the fillets on them and it's just open. Then the last sketch is just a single pad here which is likely for the whole positioning. So we don't have anything that instantly allows us to just focus on this area, which means that the next step that I want to do is, I want to go back into my design and I'm going to start a new sketch. So I'm going to start a sketch on this bottom face and I want to connect this geometry. So I'm going to come in and create an arc, then we use a three-point arc and go from here to here, and I'll simply just drag the arc for now, but then I can either use the tangent option or the concentric option. If I select concentric and then grab this arc, knowing that this is a full circular profile, that'll give me everything I need. While we're in here, because we already have this outer section, it makes sense for me to go ahead and just complete it on the inside as well. I don't know if I'll need it yet or not, but it saves me the trouble from coming back out here. Again, we'll use the concentric option, making this concentric and then finishing that sketch. I'm going to rename sketch eight, and I'm going to call this bottom profiles. So this way I know exactly what that sketch is, and let's go ahead and save this and then navigate back to our manufacturing workspace. In here, you'll notice our tool paths have a warning on and we'll have to go into actions and generate, and it'll regenerate those and because we simply added a sketch, it's not going to affect anything. So now we have our external 2D contour which allowed us to rough and finish the outside, we have our adaptive tool path which allowed us to rough the inside pocket. Now, what we want to do is, we want to create an adaptive toolpath to finish off the inside of that pocket. So I'm going to right-click and duplicate this one because I'll be using the same tool, then I want to make an edit to it. The edit is going to be in our chain selection. So now I want to select the chain at the bottom, and again we need to make sure we're focusing on the correct side. We're going to go into our heights. This time because it is at the bottom, we can use our selected contour, and then I'm going to say okay and take a look at the toolpath that's created. Now, we're coming in and we're clearing everything out and remember at this point, we haven't actually finished the floor. So if we want to finish the floor at this time, we'll have to make some adjustments to the parameters inside of our pastors section. For axial stock to leave, we'll set that as zero, and this tool go all the way down to the floor. Now, this is assuming that it can actually get into these corners and if we inspect and measure the radius value on these corners, we can see that the radius is 187, which means that the half-inch end mill is not actually able to get into that corner. We will need to come back in and do some rest machining or do a contour operation to clean that out with a smaller tool. But that's okay. Let's just do one last simulation of everything we've done so far. We'll step past the first one, we'll step past the second one, and we'll play it past the third operation. Notice it's taking a lot of time doing that helical entry because it doesn't know all that other material has been removed yet. It is going to the wall, but remember we are leaving 0.02 there. But in order to do this, let's come back in, and make one last change to our geometry using rest machining. The tool diameter it's looking for is really trying to calculate how much material is left on the wall and not on the sides. So this isn't actually giving us what we want because it thinks that the material is going to be left on the sides and that's what it's going to calculate. So in order to keep the tool down a bit farther, we're going to change this top of stock height to a selected contour. This means that it's going to start the clearance values and it's going to start cutting from that area. If we say okay, notice that it's giving me a warning, the clearance height must be above the retract height. So my top height is this selected contour, the clearance height is currently set to selection, but we're going to make this set from the retract and then we're going to say okay. So now, our helical entry is much smaller and if we simulate this, we can step through the first operation, step through the second, and now the tool is going to wrap it down and then move. It's showing is red because it thinks that it might be entering stock, but we've already removed that material and we know that there's nothing there left for it to hit. We just need to be aware of and concerned with whether or not the tool is going to move horizontally or if it's going to move back up to that clearance plane after this operation. Since we know we're going to move it up to a different position and we're going to focus on the cylindrical area. Everything in this area is going to be fine, we don't have to worry about the tool hitting anything because there's no additional geometry in the middle of our part. So for me, everything looks okay. I'm going to make sure I'm at a home view. Make sure that I save my file before moving on to the next step.
