OK maybe this was too aggressive even for Adaptive Clearing ;)

[Chaz]

Happy New Year all,

A quick video of some aluminium work, where I pushed adaptive clearing a bit too far. Parameters were DoC 15mm, stepover 3.2mm optimal.

Interestingly it was the spindle that overloaded and shut down rather than chip weld or the usual horrors..

What is the spindle rating? I was surprised the endmill did not break when the machine was still moving later. The whole 'wood' area moves but the endmill remains, incredible.

[Washout]

Hi Chaz - that was the 2.2KW water-cooled variant.

As Jazz says if the bed was moving and allowing the cutter to take more than the desired 3.2mm then that might account for the spindle cut out. I've generally found that 8mm tools tend to survive very rough treatment, whilst 6mm and below don't. Last time I used an 8mm when something went wrong it welded itself into the plate and the machine then started walking itself off the table under spindle power, which was pretty scary, but the tool stayed intact.

I was even more grateful this time that the part wasn't ruined as I'd just finished cutting on the underside (hence the 4 hold down screws). This was the "cut out" toolpath in essence.

[Chaz]

Hi Chaz - that was the 2.2KW water-cooled variant.

As Jazz says if the bed was moving and allowing the cutter to take more than the desired 3.2mm then that might account for the spindle cut out. I've generally found that 8mm tools tend to survive very rough treatment, whilst 6mm and below don't. Last time I used an 8mm when something went wrong it welded itself into the plate and the machine then started walking itself off the table under spindle power, which was pretty scary, but the tool stayed intact.

I was even more grateful this time that the part wasn't ruined as I'd just finished cutting on the underside (hence the 4 hold down screws). This was the "cut out" toolpath in essence.

Awesome.

As soon as I get my misting system working on my little Denford, I want to do the same. I am however limited to about 4400 RPM via a 1.5KW AC Servo, so my level of adaptive is not the same but Im keen to see how far I can push.

[JAZZCNC]

Awesome.

As soon as I get my misting system working on my little Denford, I want to do the same. I am however limited to about 4400 RPM via a 1.5KW AC Servo, so my level of adaptive is not the same but Im keen to see how far I can push.

Use larger cutter if possible and you'll stand more chance. Smaller cutters need the high rpm and will fail quickly if run with low rpm at high feeds.

[Chaz]

Use larger cutter if possible and you'll stand more chance. Smaller cutters need the high rpm and will fail quickly if run with low rpm at high feeds.

Currently use 8mm roughing and 10mm finishing end mills. I think Ive got a 10mm roughing one I can try.

[Chaz]

Use larger cutter if possible and you'll stand more chance. Smaller cutters need the high rpm and will fail quickly if run with low rpm at high feeds.

So I managed to get one set of cuts done and then snapped an 8mm roughing mill on the 2nd try.

Just uploading the vids now.

[JAZZCNC]

What is the spindle rating? I was surprised the endmill did not break when the machine was still moving later. The whole 'wood' area moves but the endmill remains, incredible.

Wood moving was the only reason endmill was saved he's lucky lucky boy . .

[Chaz]

But did you move the stock so it thinks in different place or possibly didn't zero Y axis exactly right because to me it looks like it's doing positional move and thinks stock edge is in different place to where actually is. The fact the tool path retract distance when moving is so close doesn't allow much room for error.!

Nope. Just Z. I'll do another on the weekend.

[Washout]

Hi All,

Just as a way of update from the OP here are two related videos - one for Fusion 360 CAD/CAM and one for the entire cutting job, with successful adaptive clearing using 6 and 4mm 3 flute roughers @ 10 and 5mm DoC respectively:





Hopefully the more aggressive cutting has me off of the "cruelty to cutters" watch list ;)

[Chaz]

Hi All,

Just as a way of update from the OP here are two related videos - one for Fusion 360 CAD/CAM and one for the entire cutting job, with successful adaptive clearing using 6 and 4mm 3 flute roughers @ 10 and 5mm DoC respectively:





Hopefully the more aggressive cutting has me off of the "cruelty to cutters" watch list ;)

Awesome, nice result there.