SeymourDumore
Diamond
- Joined
- Aug 2, 2005
- Location
- CT
Guys
I'm starting a relatively large production job on A2.
I have machined quite a bit of A2 before in small batches, one-two pieces, small amount of removal etc etc. I can cut it without issues so not afraid of it at all.
But!
Since this is a production run, I'd like to ask a couple general questions regarding the roughing only.
1: The obvious... speed and feed
2: Coolant or not
3: tooling: serrated rougher or std endmill
4: Stepover
Conditions:
The tool in question is:
1/2" EM.
Max DOC is .450
Very minimal amount of slotting
good access to features, good chip evacuation so no chip recutting
part is held in hard jaws .350 deep, so it's solid.
Stock size is 3"long x 2"wide x 7/8 thick
Currently running a serrated rougher @ 400SFM, .450 max DOC, 40% stepover, .003IPT
Machine is a 40 taper, 7500RPM and gearbox.
I have the ability to flood, minimum oil, airblast or all of the above at my disposal.
The only thing I need to worry about is that all features must finish +/-.001, and stay that way after unclamping.
I have made 20 pieces so far as a test and not overly happy about the tool life on the rougher.
Holding the tolerances were a piece of cake, but I am about to reprogram the part for the long run ( 750 pcs total )
Would an HSM toolpath be OK, or would it put too much stress into the part?
Ditto for dry machining.
Finish part will be hardened to RC60+ and then ground on ... well, on a whole bunch of surfaces as some of the features are .0004 total, so I'd like to do everything
I can to make it easy on the poor guy doing the grinding.
Any suggestions are welcome!
Thank You
I'm starting a relatively large production job on A2.
I have machined quite a bit of A2 before in small batches, one-two pieces, small amount of removal etc etc. I can cut it without issues so not afraid of it at all.
But!
Since this is a production run, I'd like to ask a couple general questions regarding the roughing only.
1: The obvious... speed and feed
2: Coolant or not
3: tooling: serrated rougher or std endmill
4: Stepover
Conditions:
The tool in question is:
1/2" EM.
Max DOC is .450
Very minimal amount of slotting
good access to features, good chip evacuation so no chip recutting
part is held in hard jaws .350 deep, so it's solid.
Stock size is 3"long x 2"wide x 7/8 thick
Currently running a serrated rougher @ 400SFM, .450 max DOC, 40% stepover, .003IPT
Machine is a 40 taper, 7500RPM and gearbox.
I have the ability to flood, minimum oil, airblast or all of the above at my disposal.
The only thing I need to worry about is that all features must finish +/-.001, and stay that way after unclamping.
I have made 20 pieces so far as a test and not overly happy about the tool life on the rougher.
Holding the tolerances were a piece of cake, but I am about to reprogram the part for the long run ( 750 pcs total )
Would an HSM toolpath be OK, or would it put too much stress into the part?
Ditto for dry machining.
Finish part will be hardened to RC60+ and then ground on ... well, on a whole bunch of surfaces as some of the features are .0004 total, so I'd like to do everything
I can to make it easy on the poor guy doing the grinding.
Any suggestions are welcome!
Thank You