5-Axis Machining

For my 5-axis project I wanted to mill a 20 sided die (D20). First I had to design a D20, I did this using 3D sketch in fusion 360 I first made a pentagon and had all the edges meet at a point in the middle above the pentagon. Then I had a line go below the pentagon and made a second one, then I connected them and had the bottom pentagons angles meet at a point below that pentagon. I made all the edges the same length. After I made the sketch of the D20 I patched all the sides then used the surface stitch to made all the patches solid. 

Once I finished designing my die I added a Penta Pocket Nc, because that was the machine we are using to mill the die. Then I used a construction plane to make a sketch in the middle of the die, so I could make the out line where the endmill would cut. I did this 6 times to cover all the sides of the die.

Now I moved on to the machining tab in fusion to make the toolpaths for my D20. For all my toolpaths I changed the surface speed to 300 ft/min and cutting feedrate to 10 in/min because that's the safest settings for the pocket Nc. 

My first tool path was roughing the upper part of my die to get rid of most of the excess stock. Then my next 5 toolpaths are a finish path on the top of the D20. 

My next 5 toolpaths is roughing again but this time the sides of the die, so that I could then have 10 finish paths smooth out the edges. 

The next 5 paths are roughing the bottom of the D20.  Then the final 5 are finishing the bottom waiting to be cut off. 

Now that all of the tool paths are finished I postprocessed them into g code and instead of just going and running the program I put the g-code into the Penta Simulator (https://sim.pocketnc.com/). Fortunately I caught that the Penta simulator had the stock not in the middle of orientation of the machine even though it was in the fusion simulator. So, I want and checked the where the origin was and as i suspected it was off of the middle of orientation for the machine. 

Instead of restarting form the beginning I fixed this problem by using the move tool to move everything to the correct position. I did this by first making a sketch point where I wanted the sketches to go then I made patches of the sketches I needed to move then used the move tool point to point to move the patches by clicking the origin point (where the sketch was) and the target point (where the sketch needed to be).  Lastly I then projected the patches to be the new sketches. 

Now when I tested the g-code in the Penta simulator everything looked how it looked in the fusion simulator and there were no problems.

Now it was time to actually mill the die, once everything was figured out in the simulators the milling part went by easy without much difficulty. 

After my code was done running the D20 was left on a tab that I had to cut off and grind down.