Need advice for tool and strategy for steel c45 roughing

Hi,

need your help, guys. Have a medium rpoduction run for attached part but it goes really slow with my specialists so i want to ask advice overseas

Below is a image of part. The steel is c45 steel, the sizes in millimeters. With current strategy we waste around 1 hour for 1 part - the strategy is simple - mill with 2d raster from top, then machine every side. But i'm sure that that part can be done in half an hour or less with an appropriate tool and strategy.



Im not a CNC programmer but i want to try the different strategy, i have attached on the image below. I think, its clear - that we rough from these 2 sides, then place it like on the top image - cut the slot, make finish pass on plane, drill the holes and chamfer. The the other side with 52mm face mill. Done.



Can anyone advice me a good price/quality mill on that? I have an 12000rpm/18.5kW spindle and want to go at least with 150m/min (500sfm) and 1.5-2m/min of feedrate (80inches per minute) with Ae=5-10mm and Ap=20-45mm. Is there any way i can calculate if my spindle power is capable of such speeds and feeds?

But the main problem is - the price. I cannot afford 1mill per part. I need it to machine at least 20-30 parts or even more to make some profit. So the Sandvik with 800USD is not my choice, i think

The surface finish for that part is not a matter, because of further sanding and chem.oxy, but we need at least ra6.3 on base planes and slot

You could use a decently sized rougher if you want to just get them out for a finish pass. I would recommend something of decent quality, don't buy the real low end ones if you want to get a lot of parts per mill.

2 mm Diam, 2 mm Shank Diam, 75 mm Length 9119688 - MSC

Yes kicking it on it's side and side cutting that radial form is the way to go. I would go with a 3/4" dia variable helix end mill (or 20mm in your case).
Heck, maybe even a slitter to cut that slot while it's there. But those are pricey.

Thanks, could you point me for some brands and models I can look onto? I viewed a Seco performance series, but those are pricey and will not fit our countries machine hour pay rate.
And what will be the approximate lifetime of mill, using it on its maximums? For maximum, I mean milling on Ae of 40% of dia and Ap - all of the cutting height.

And I'm curious concerning 2mm dia. rougher. Is your info correct?

I am not sure why the link posted like that, its actually a 20mm dia x 75mm loc made by Hertel.

This Walter-Protyp 20mm rougher is decent and a bit cheaper for what you need:

20 mm Diam, 20 mm Shank Diam, 75 mm Length 36227247 - MSC

nihilistic said:

I am not sure why the link posted like that, its actually a 20mm dia x 75mm loc made by Hertel.

This Walter-Protyp 20mm rougher is decent and a bit cheaper for what you need:

20 mm Diam, 20 mm Shank Diam, 75 mm Length 36227247 - MSC

Click to expand...

This seems reasonable to me, but if tooling cost is important perhaps a 16mm x ~50mm tool will work, at a somewhat lower price and MMR.

What brands are available via efficient distribution in ukraine? (I can often get a better tool at a better price from my local tooling shop than online - but circumstances in Ukraine may be rather different.)

YG-1 has roughing endmills I rather like, but I've not run life tests on them, and I have no idea if you can get them in Ukraine.

Thanks for a responses!

We have locals here who gets the cutting tools directly from US with no official notification. So i get very good prices for Inch tools and the brands are various, YG-1, Walter, Vallorbe, Kenna etc.

We have used YG-1 Tank power 3\4 for roughing but it's not a solid carbide, so it quickly cracks on feeds more than 750mm/min. Will try solid carbide series from YG-1

1 inch3 / hp

evidence_UA said:

Thanks for a responses!

We have locals here who gets the cutting tools directly from US with no official notification. So i get very good prices for Inch tools and the brands are various, YG-1, Walter, Vallorbe, Kenna etc.

We have used YG-1 Tank power 3\4 for roughing but it's not a solid carbide, so it quickly cracks on feeds more than 750mm/min. Will try solid carbide series from YG-1

Click to expand...

In that case reduce the speed a bit and increase the depth of cut and stepover, to up the metal removal rate.

IMO that sort of job needs a TOUGH cutter, and IME Tank Power is the way to go, especially when milling those radii standing upright.

Spindle speed isn't everything, stuff that cutter in and make it work, .................and I know those YG Tank Powers will really hoss it off, .......have you run them to YG's parameters. FYI eg http://www.cutwel.co.uk/FileDepository//ProductId - 85/Cutting Data GA938.pdf

For further data go here Tank Power Powder Metal | Milling Tools Supplier | Cutwel Ltd, find the cutter you are using click on that and you will see a tab ''Technical Information'' click on that and you get a drop box one of which is ''Cutting Data''


Personally I wouldn't give you the time of day for Hertel - let alone at the prices MSC want.


PPPPPPPPPPPPPPPPPPPS If you want to really get in there and hoss it off look at at this date for a roughing Tank Power http://www.cutwel.co.uk/FileDepository//ProductId - 93/Cutting Data GAA26.pdf

Run a rougher then a finishing cutter, ...... that will improve tool life no end