So, I know it doesn't take much to cut aluminum but I'm looking or the best bang or the buck. We have a 12000 RPM Spindle and they don't like to run it wide open. Mainly 6061 Aluminum Plate. A lot of slotting and then finishing with same tool. Don't need anything real aggressive but long lasting and cost effective are key.
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Aluminum Tooling
- Thread starter MachMac
- Start date
- Replies 7
- Views 1,585
cb750chris
Aluminum
- Joined
- Dec 9, 2018
- Location
- Prescott
The ones above for sure and I like these guys too:
CarbideToolSource.com
No affiliation, just good quality, good prices, and supporting a small shop in the US.
Sent from my SM-N960U using Tapatalk
CarbideToolSource.com
No affiliation, just good quality, good prices, and supporting a small shop in the US.
Sent from my SM-N960U using Tapatalk
Orange Vise
Titanium
- Joined
- Feb 10, 2012
- Location
- California
We go through over a dozen AlTiN coated endmills cutting steel in the same amount of time it takes to go through one ZrN coated endmill for aluminum (based on our tool timers that track time in cut). That's a conservative estimate. In some cases it's more like 20-30, depending on the application. Cost of the tool is inconsequential when it comes to aluminum. We use Maritool's 45 degree helix variable 3-flute with a rainbow ZrN coating.
If you want your process to be dead reliable, start out with a good tool, and then put it in a good holder and pay attention to coolant flow and good toolpaths. In almost every case IME, tool breakage is caused by chip welding due to bad coolant flow or tool burial. A toolholder with TSC coolant jets in the nose helps a lot, but there is, of course, cost associated with using TSC all the time. We only use it when pocketing. Running the coolant slightly rich, e.g. 10% instead of 7%, helps too, but there's cost associated with that as well.
If you want your process to be dead reliable, start out with a good tool, and then put it in a good holder and pay attention to coolant flow and good toolpaths. In almost every case IME, tool breakage is caused by chip welding due to bad coolant flow or tool burial. A toolholder with TSC coolant jets in the nose helps a lot, but there is, of course, cost associated with using TSC all the time. We only use it when pocketing. Running the coolant slightly rich, e.g. 10% instead of 7%, helps too, but there's cost associated with that as well.
mhajicek
Diamond
- Joined
- May 11, 2017
- Location
- Maple Grove, MN, USA
Just for kicks, calculate how much time you're wasting not running wide open, and see how long that would take to pay for a replacement spindle.
Exactly. "they" are not very smart.
MaxPrairie
Hot Rolled
- Joined
- Jul 9, 2015
Ask machine rep for a duty load chart for the spindle. Might get a ton more life at 11,500 rpm.
mhajicek
Diamond
- Joined
- May 11, 2017
- Location
- Maple Grove, MN, USA
I did precisely that when I got a 15K RPM Haas in 2015. They said no duty cycle, run it balls out. So that's what I did, averaging several hours a day at top speed, never a problem.
Not I've got a 50K RPM Haas, and I run it balls out too. Really cuts down on cycle times with small tools.
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