Been doing a bit more testing tonight and decided to see the results on aluminium with 5 different type's of cutters.
1 - Alimaster 2 flute 8mm
2 - HSS 2 flute 6mm
3 - HSS 6mm ripper
4 - Solid carbide 2 flute 6mm
5 - K2 coated 3 flute 6mm
Ran them all at the same speed and feeds to see which gave the best surface finish results, spindle speeds 4000rpm and 6000rpm, feedrate 300mmpm, side cutting taking 0.5mm off which is what i would normally leave for finishing, depth of cut dependent on cutter length. Tried both climb and conventional milling with each cutter.
1 - Alimaster - Certainly removes material easily but not the best surface finish.
2 - HSS 2 flute 6mm - Cuts nice but still get the chatter lines, surface finish similar to alimaster.
3 - HSS 6mm Ripper - Does what it says on the tin, rips the material off very easily without producing loads of swarf. Finish not good but definitely my choice for roughing.
4 - Solid carbide 6mm 2 flute - This gave a poor finish, carbide is very hard and sounded like it when it was cutting. Kept leaving lots of very small but even ridges. May need to be pushed harder to get best results.
5 - K2 coated 3 flute 6mm - Cheapest cutter of the lot and gave the best results, i put it mainly down to it having more flutes than the others which helps with the intermittent cutting. I have not got any 4 flute cutters but i will be getting some to try.
A few photo's attached, did not take photo's of all the results as some started to look similar to others so did not see much point!
Conclusion - More flutes give a better finish but a ripper is best for roughing out, also need a more sturdy machine to give a better surface finish, but now at least I know what surface finish the machine is capable of and what to expect from it.
Interesting Steve, i use the alu-power alot also, ive noticed that when i use them to mill say a pocket the bottom face is never super clean, it alway leave swirl marks but when do a finishing pass of a profile on some 12mm alloy DOC 0.1mm spindle at 12000 rpm feed at 600mm/min i get a mirror finish. im also going to try some k2's seeing as they are on offer at the mo.
On your video have you limited you coolant flow or is that what the pump flows normally?
I see, i have concocted my own coolant system from a parts washer, and what i have done is position it under where i am cutting, at the moment tho i have used some polythene sheet as a catch to funnel the coolant back into the parts washer and i have made a removable screen that goes around the spindle from some clear plastic that is used for doorway screens.
When i get five ill pop some pictures up on my thread
Just a quick question. About to build my own CNC at last! What was the size and part nos for your THK linear Slides? Can you recommend a good supplier for these
in the uk?
The Following User Says Thank You to Jonathan For This Useful Post:
Thanks Jonathan - I'll look into these other brands
I am back....!
Got a little bit sidetracked last year building an extension on my house, all finished now so hopefully more time for playing in the workshop
I get quite a few emails regarding this machine build so if anyone does have any questions then put them on here so that everyone can benefit from them.
Well Thanks to your "inspirational" build log I've finally got my design sorted out http://www.mycncuk.com/forums/showth...gn-Build/page4 and now trying source aluminium plate for the build. And I've got bathrooms to refurbish
http://www.aluminiumwarehouse.co.uk/cutting_calc.php - they sell cast plate at what seems a reasonable price.... Fantastic build by the way Steve I am going to shamelessly plagiarise!
BUILD LOG: New Build - For Your Amusement - MK-2 buildBy Karl in forum DIY Router Build LogsReplies: 11Last Post: 11-06-2012, 07:34 PM