3 Axis Challenge

For this challenge I was tasked to design something in Fusion 360 that I could cut out of a 6"(X) x 3.5"(Y) x 2.5"(Z) on a 3 axis machine on the shop floor. 

My parameters are it has to be less than the block, includes at least 1 blind hole meaning a hole that doesn't cut all the way through the part, at least 1 thru-hole which is a hole going all the way through the part, at least 1 step through Z meaning that one side of the piece is higher than the other on the top. The way I did that was making a door stop with a face on it so I could have the slant as my step in Z and my through and blind holes. 

For my first part I did a 2.5x2.5 with a 10 degree slant in the middle of the 6in block and had a 3.5in base. I made my eyes .63 in diameter, the nose was originally a triangle and the mouth was less curved but we didn't have tools that were slim enough to fit those shapes so I had to adjust it.

For my updated part I made it a 3x3, had a10 degree slant across the top and I used a .35in base. I added a smiley face to the block with the diameter of the eyes being .63in, the nose and mouth each having a .25in radius. The eyes from the side of the face are .80 from the side and .60 from the top. The part itself is 1.5 away from the edge of the block on both sides and is .60 from the top of the block and .30 from the bottom edge.  

Cadding the part

When I went to CAD my part it was a lot of trial and error from trying to figure out where to put the starting point to tool numbers and what machine we'll be on.

For my first toolpath I used T11 which is a 3/4" Flat Endmill to cut down the block to the correct height and in that pass it did the slant. 

For my second tool pass I used T4 to do the pockets/all my holes.

For my third tool pass I used T8 to remove the steps on my slant.

For my lst tool pass I used T12 to chamfer my edges and holes but there was an issue with this, in programming I aligned the tip of the tool to the edges instead of the side of the tool so it didn't chamfer my part properly.

Cutting the Part

After I designed this and ran the simulations I exported and looked over my Gcode, Gcode is the code that goes into the 3axis CNC machine to make the machine cut the part, the machine follows the code. I had to change my starting point to the back right corner and change my tools to match the tool numbers on the machine then I was good to go. And this is how my part turned out.