Hey all
I'm at my wits' end trying to avoid chip welding while helical ramping into 6061. No other issues roughing or finishing, just ramping into pockets. I'm using 1/4" 3 flute at 10k RPM with a 5 degree helix and ramp diameter of .2375" (~95% tool width according to the CAM). I've tried both HSS and ZrN coated end mills, and feed rates of 20 and 40 IPM. Using air blast + koolmist for cooling, but it's clearly rubbing/melting the aluminum and getting welded onto every end mil I try Lowering the helix angle to 2 gives an ear-searing squeal which can't be good...
Again, works perfectly for other operations; can side mill all day long without issue or heat. Any ideas on what to try next?
I'm at my wits' end trying to avoid chip welding while helical ramping into 6061. No other issues roughing or finishing, just ramping into pockets. I'm using 1/4" 3 flute at 10k RPM with a 5 degree helix and ramp diameter of .2375" (~95% tool width according to the CAM). I've tried both HSS and ZrN coated end mills, and feed rates of 20 and 40 IPM. Using air blast + koolmist for cooling, but it's clearly rubbing/melting the aluminum and getting welded onto every end mil I try Lowering the helix angle to 2 gives an ear-searing squeal which can't be good...
Again, works perfectly for other operations; can side mill all day long without issue or heat. Any ideas on what to try next?