- Mar 16, 2023
Hey guys I'm looking for some advice on a job I'm running at the moment, it's a toothed pulley similar to the htd or supercharger belt profile and the root of the tooth is almost a 2.5mm rad. I've only got 1 form cutter to cut the teeth so I'm roughing out the teeth with a 5mm ball to try to extend the form cutters life. The issue is the pulleys are fairly long (80mm) and have 50 teeth so roughing out the teeth is fairly slow. I'm running the cutter at 1200mm/min and ramping down in 6 passes but it still takes at least 40min per part. I've got a fair few to do and I'd rather not have the machine tied up for weeks on this job, anyone got any ideas to make it faster? Ideally I'd use a 5mm CRB drill and drill 50 holes in the face of the bar then turn the od to final diameter, but the stock I've got is only 1mm bigger than the diameter of the finished part so that's not an option this time. I've got some 4 flute ball nose coming that the tooling rep claims handle slotting fairly well but I'm doubtful it'll last as long as the 2 flute I'm currently using. I've wondered about tilting the endmill at 30-45° around the lathe y axis (mill-turn machine with a rotating milling head - mazak integrex i400) and dragging the cutter away from the chuck at full depth, in my mind it should help with chip clearance and reduce the amount of work the centre of the tool has to do. Anyone tried this? Can anyone point to any reading I can do on the topic, a quick Google search doesn't turn anything up.