HELP!?I have been trying for three days now to use a solid uncoated carbide slitting saw with zero success. Cutting .016 wide slits in 6AL-4V Ti bar. Saw has been 1.75 dia and 2.25 dia two different tries. The slits are going .2225 deep, 63 of them around a diameter of 1.720 tube end.
I have tried various chip loads, feeds and speeds. I have broken 7 saws....at nearly $100 a pop. At this point it would have been cheaper to write the customer a check and tell them have someone else do it. I have tried clpt in the millionths up to even .0005. I have tried cutting full depth of cut, two depth cuts...and even 4 depth cuts.I have been conventional cutting...that failed...even with zero more ideas attempt climb cutting( yes I know that is not the smartest thing with no keyway to lock the cutter in) But nothing has worked.The customer needs 3 of these parts right away...and it is aerospace...so as of now EDM or laser is not allowed. That would leave a casting on the part which they cannot have. Anyone out there that can possibly point me in a direction that will work for getting these parts out the door, your help would be very much appreciated.
In the morning I am to try cutting with a carbide cutter a partial depth of .040...then follow through with a HSS cutter 2.75 dia with a shop made
arbor that can support the majority of the flimsy blade at full depth. All i can think is super slow RPM and a chip load of maybe .0005 and try to chew through these three parts. Hopefully someone out there can give me a better faster and more successful direction to go.
I have tried various chip loads, feeds and speeds. I have broken 7 saws....at nearly $100 a pop. At this point it would have been cheaper to write the customer a check and tell them have someone else do it. I have tried clpt in the millionths up to even .0005. I have tried cutting full depth of cut, two depth cuts...and even 4 depth cuts.I have been conventional cutting...that failed...even with zero more ideas attempt climb cutting( yes I know that is not the smartest thing with no keyway to lock the cutter in) But nothing has worked.The customer needs 3 of these parts right away...and it is aerospace...so as of now EDM or laser is not allowed. That would leave a casting on the part which they cannot have. Anyone out there that can possibly point me in a direction that will work for getting these parts out the door, your help would be very much appreciated.
In the morning I am to try cutting with a carbide cutter a partial depth of .040...then follow through with a HSS cutter 2.75 dia with a shop made
arbor that can support the majority of the flimsy blade at full depth. All i can think is super slow RPM and a chip load of maybe .0005 and try to chew through these three parts. Hopefully someone out there can give me a better faster and more successful direction to go.