Reason I am asking is because all of the "recommended" speeds and feeds are basically thrown out the window with the length of tools we use at our shop. I just started working at a new shop two weeks ago and I will be doing programming and some setup. I worked in a shop for years but we never had to use tools this small and long before, we rarely worked with aluminum either.
Anyways... Most of the parts we run are five inches thick and require a ton of roughing.
Basic rundown of the tools I've seen being used so far...
1" carbide endmill 2 flute (sometimes 4 flute )
3/4" carbide endmill 2 flute (sometimes 4 flute )
1/2" carbide endmill 2 flute (sometimes 4 flute )
1/2" carbide ball endmill 2 flute
3/8" carbide ball endmill 2 flute
1/4" carbide ball endmill 2 flute
All of the tools listed above are often sticking out by 3",4" and sometimes 5". Chatter is sooo bad.
They are using 6500 RPM at 50IPM with a DOC of .050" (with all of their tools ) which sounds like shit while running... obviously. I've been telling them their chip load is not enough, but "thats the way they have always run" so they don't want to change anything...
With the given tools listed above, what SFM should I be using while calculating speeds/feeds (keep in mind the length of the tools)? Obviously we must run them differently compared to tools that are only sticking out an inch or two.
We also drill the back sides of the parts with a .201 jobber drill and it takes forever with the rpm/feed they are using. I don't remember off hand what they are though. What SFM would be best for this application? Length is really of no concern with this since there aren't any chatter/breakage issues, only gumming up the tool. Are there any drill mfg's that offer this size drill with thru tool coolant?
Insert cutters... Surely these would help out with higher feeds and deeper DOC's... One of our mills spins up to 10,000RPM with thru spindle coolant, the other is 7,500 without TSC. As of right now there is no budget with tooling, as far as I know. I am sure they will be willing to spend some money on some quality tools that will outlast and outperform what they are currently using.
Before you guys ask, what the hell is this place doing? The machine shop is only a small part of the production there, and it is often neglected although being very important. The parts we machine are not the end product so surface finishes and cycle times are never questioned.
Basically, if you had an unlimited amount of money for whatever tools to rough/finish large parts out of 6061, aside from new machines, what would you recommend?
Damn, I sound like I've never done this before...
Thanks in advance for any replies.
-couch
Anyways... Most of the parts we run are five inches thick and require a ton of roughing.
Basic rundown of the tools I've seen being used so far...
1" carbide endmill 2 flute (sometimes 4 flute )
3/4" carbide endmill 2 flute (sometimes 4 flute )
1/2" carbide endmill 2 flute (sometimes 4 flute )
1/2" carbide ball endmill 2 flute
3/8" carbide ball endmill 2 flute
1/4" carbide ball endmill 2 flute
All of the tools listed above are often sticking out by 3",4" and sometimes 5". Chatter is sooo bad.
They are using 6500 RPM at 50IPM with a DOC of .050" (with all of their tools ) which sounds like shit while running... obviously. I've been telling them their chip load is not enough, but "thats the way they have always run" so they don't want to change anything...
With the given tools listed above, what SFM should I be using while calculating speeds/feeds (keep in mind the length of the tools)? Obviously we must run them differently compared to tools that are only sticking out an inch or two.
We also drill the back sides of the parts with a .201 jobber drill and it takes forever with the rpm/feed they are using. I don't remember off hand what they are though. What SFM would be best for this application? Length is really of no concern with this since there aren't any chatter/breakage issues, only gumming up the tool. Are there any drill mfg's that offer this size drill with thru tool coolant?
Insert cutters... Surely these would help out with higher feeds and deeper DOC's... One of our mills spins up to 10,000RPM with thru spindle coolant, the other is 7,500 without TSC. As of right now there is no budget with tooling, as far as I know. I am sure they will be willing to spend some money on some quality tools that will outlast and outperform what they are currently using.
Before you guys ask, what the hell is this place doing? The machine shop is only a small part of the production there, and it is often neglected although being very important. The parts we machine are not the end product so surface finishes and cycle times are never questioned.
Basically, if you had an unlimited amount of money for whatever tools to rough/finish large parts out of 6061, aside from new machines, what would you recommend?
Damn, I sound like I've never done this before...
Thanks in advance for any replies.
-couch