We have a long standing order for an aircraft part where we remove approximately 75% of the material with (2) 1/2" diameter endmills. Material is 6al4v. Im averaging about 20pcs per tool utilizing dynamic tool paths around the profile.
This job was running when I got here, and the person that started the project is no longer here so Ive been working my way through some of the issues in the process. At this point Ive tried a few different tools and manufacturers but so far, am have the most success with my 5flute reg length and 6 flute stub Titan brand endmills(what an unfortunate brand name). Ive thought about trying to rough the profile with an insert tool but my exploratory toolpaths show a much greater cycle time and even if I use a larger diameter insert tool, ill still need to come back in with the 1/2" tool to clean out the smaller rads.
Curious, who is making the best endmills for milling titanium and in which configuration? mainly looing for tool life improvements.
Currently running about 350ish SFM and .0067chipload. 6% radial DOC on an OKK Horizontal
Thanks In Advance.
We are machining these parts in our 5axis fanuc robodrill and our rep from Dataflute had us try the SSI-7 end mill and last I checked we were well over 100 parts and still going. It's a 1/2 end mill with a 1-1/2 l.oc. and it's performing much better than the one we were using before which I don't quite remember what it was. It's a serrated end mill but we're using it to rough and finish. I can find out exactly whatthe cutting conditions are tomorrow. We have used Garr and Helical and these Dataflutes are phenomenal.