DTSFab.com (Desert, Trail and Sand)
Machinery, Trailers, Toyhaulers and Motorhomes => Machinery Builds => Topic started by: fabr on February 25, 2010, 11:21:03 AM
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Using 2 flute TiN coated end mill. .375,.500 and .750 sizes. CUtting aluminum dry. What is your opinion on speeds/feeds/depth of cut and cut offset? AlibreCAM has a table but it seems to be a bit too aggressive to me. Looking for opinions other than -turn the coolant on dummy! rofl
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why are you cutting dry? Do you have at least a mist setup because anything
will help greatly. If you buy carbide you can run them wfo on aluminum as far as the rpm goes. should be able to take about .250 cut on the .500 and .750 endmills with about a .003 chip load per flute. so at 3000rpm lets say, that would be about 20 ipm on a 2 flute endmill.
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Man, to be honest that a very broad question. Id run coolant if you can! Aluminum will just weld its self to the cutter. At least run a mister but recomend a flood. If you cant run coolant you will need to slow it all down, Dry, cut below in 1/2.
40 taper tooling ?...
High speed or carbide? (even though its coated this does matter)
good set up, rigid machine?
HSS...
Depth of cut... 1X the diameter with coolant.
Feed... .002 - .003 per flute, per rev.
RPM... 750 SFM (aluminum)
to find; RPM= (3.82 X sfm) / diameter of cutter
to find inches per minuite(ipm), RPM X feed per rev.
Example: 1/2" 2 flute cutter HSS...
3.82 X 750 = 2865
2865 / .5 = 5730rpm
ipm = 5730 X .006 (per rev) = 34.38 ipm
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considering you are a noob there fab-star (that's how I think of you in
my mind), I would start with a smaller depth of cut and see how your machine
reacts. Can probably shoot for about a 70% stepover. And you should program
it at the machine like a real man!!!
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Really I'm just screwing around. Doug,those formulas are what I was always taught with coolant and are what the AC has as a standard database. It can be easily changed. . I'll of course be running coolant but just hadn't gotten the hydrosweep chip collector/coolant in place yet. That might be another whole new can of issues I need to avoid right now just so I can make it to LS-with a fricken car this time. I'm tired of this bumming a ride crap. LOL!!. Thought I'd try one dry or near dry as I have a mist setup for the bridgeport just to get going for now. Bennyhanna, I agree completely also. I've already run a couple test items dry. Won't be as nice as I'd like but will serve the prototype well enough for sure.
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considering you are a noob there fab-star (that's how I think of you in
my mind), I would start with a smaller depth of cut and see how your machine
reacts. Can probably shoot for about a 70% stepover. And you should program
it at the machine like a real man!!!
I call BS on this! LOL!!!!!
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i program everything at the machine now for 15 yrs.
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FWIW so do I :P
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I can and do for small jobs but for the majority of stuff it's just not practical.......
Faber, rig up an air nozzle to blow on the tools. This will help keep the end mill from loading up. Coolant is still preferable..........
Program it up like it was for coolant and turn the speed and feed knobs down to 50% till you get the coolant running........
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If the hydrosweep/coolant system gives me problems I'll either do air or mist but you guys have already shamed me into getting it on the machine and I'll see if it works tonite or tomorrow or,or,or............
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I can and do for small jobs but for the majority of stuff it's just not practical.......
Faber, rig up an air nozzle to blow on the tools. This will help keep the end mill from loading up. Coolant is still preferable..........
Program it up like it was for coolant and turn the speed and feed knobs down to 50% till you get the coolant running........
exactly what I do on the Bridgeport now. Thanks for the tip tho.
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What are you planning on using for coolant?
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WIndex? LOL!!!!
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What do you suggest? Soluable oil,semi synthetic or synthetic?
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What do you suggest? Soluable oil,semi synthetic or synthetic?
Perkins PRI-Cool 853-B
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What chu got against windex? I've used it for sawing and drilling. Seems to work and evaporates when done. Prolly wouldn't use it for a mill though.
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Perkins PRI-Cool 853-B
what type is that?
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3 fricken pumps. eyes bs1
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Usually something synthetic. The more warnings it has on the label the better it usually works.
For aluminum and some light steel work Valenite makes some good stuff.
I have also used Trimsol with good results.
Soluble oil is a pain if your not running all the time. A tramp oil skimmer is a must.
Get a water filter set-up. Doesn't have to be full RO, but it will make your coolant last WAY longer. Also get a refractometer and keep your mixture in check.
Funny story. Shortly after Kalifornia passed the no smoking in the workplace law I started having serious coolant funk problems on a machine. finally caught the night shift guy spitting in the machine. Seems he had switched to dipping since he couldn't smoke and was to lazy to keep a cup around. After he got done scrubbing the machine out I fired his ass.........
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Trimsol is what I have coming but soluable oil as it was what they recommended for a variety of reasons. I have a tramp oil skimmer already from my earlier days of running an automotive machine/race machine shop for quite a few years. Tank already has a slot for it. Good tip on the filter. I assume a really good whole house particulate filter would do well. Perhaps run a couple of them inline on the fill line? Refractometer is already on the way. Good call on making him clean it out first! LOL!!!!!!!!!!!!!
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And I thought you had found a viable application for use of cigarette, bs1.
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what type is that?
When your ready to buy a cutting fluid that will not go rancid and stink up the shop I'll send my sales guy your way. $18.00 per gallon and only in 55 gallon drums. It is right there with the best (Daz-Cool). Really most water soluble cutting fluids are and will work OK if you keep them skimmed and aerated. The key to any cutting fluid tank is keeping it clean.
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When your ready to buy a cutting fluid that will not go rancid and stink up the shop I'll send my sales guy your way. $18.00 per gallon and only in 55 gallon drums. It is right there with the best (Daz-Cool). Really most water soluble cutting fluids are and will work OK if you keep them skimmed and aerated. The key to any cutting fluid tank is keeping it clean.
That's what I have always understood. My previous experience was with synthetics. Skimming is vital. Aeration is something I hadn't given consideration to tho as I was using the machines every day then.This will likely set for days at a time though. I guess I could put a timer on an aerator in the sump but wouldn't it be a good idea to just run the coolant system and flush the lines and all for 15 minutes or so a day?
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That's what I have always understood. My previous experience was with synthetics. Skimming is vital. Aeration is something I hadn't given consideration to tho as I was using the machines every day then.This will likely set for days at a time though. I guess I could put a timer on an aerator in the sump but wouldn't it be a good idea to just run the coolant system and flush the lines and all for 15 minutes or so a day?
Need's the air to keep the Bactria from forming on the walls of the tank.
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We just got this filtering unit that is maintained by a vendor, it is like a pool filter with the media as the filter. It cycles the coolant 24-7. The coolant damn near lasts forever. Only need to refill it if and when it gets low.
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Yeah,it's called anerobic bacteria. Doug,I'll bet it's simple as a regular small pool filter that uses washable cartridges. Those can be had for pretty cheap. Hmmmm..............
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There you go bud! 8)
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Another funny coolant story. We were using trimsol which is blue in color.........
OSHA/hazmat inspector lady is doing a walk through inspection of the machine shop taking note of all the chemicals and crap. Basically seeing what she could fine us for. She comes over and asks what the blue fluid in the mill is. I tell her it's water and we put the blue urinal cakes in it to keep it from smelling bad. She thinks this is a wonderful idea and keeps going...........
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hehhehheeeeee
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Got a question about aeration of the coolant. Has anyone used aquarium air stones in the coolant sump? Seems like that would stop the anerobic bacteria issue pretty well. Opinions?