Epoxy granite vertical mill build log

[Chaz]

Avoid 3 flute - 2 flute or less for Alu - unless you user roughers like this which work very well - https://www.shop-apt.co.uk/3-flute-r...d-carbide.html - can go 8mm too - cheaper / easier.

HSS wont serve you well, dont bother with it.

2500 - 3000 mm/min is quick. I wonder if your spindle will bog down with this. the WOC is nice and narrow - you could try that at 10% with even a deeper DOC but Id runs slower feeds on that.

You are probably going to find that the problem is that you cant get the chips cleared - 3 flute is not as good (unless using a rougher as it breaks the chips into things that look like oversized dust).

Those feeds would work on 3 flute but chip evac is an issue.

At 24K RPM on something like a 6mm endmill (2 flute) Id run along at 1200-1500 with 20% WOC and a 10mm DOC. Endmills like working deep when doing adaptive paths - use all the of the cutting surface. Then work out how fast / wide you can go. The smaller the endmill the faster you need to spin. I'd never run your 2.2 KW under 24K RPM on Alu - no point. Dont be scared to feed quicker but only if you can get the chips out.

For 2 flute id be looking at this range - https://www.shop-apt.co.uk/end-mills...d-carbide.html - probably the 8mm or 10mm. Ditch the 3 flute stuff, its the main problem you are having.

[JAZZCNC]

Avoid 3 flute - 2 flute or less for Alu -

I'd never run your 2.2 KW under 24K RPM on Alu - no point. Ditch the 3 flute stuff, its the main problem you are having.

Oh Shit all these years I've been doing it wrong.!!! . . . . Silly me why be worried about tool life or finish quality just wap it up to full chat and let it go.!!

[Chaz]

Oh Shit all these years I've been doing it wrong.!!! . . . . Silly me why be worried about tool life or finish quality just wap it up to full chat and let it go.!!

We going there again?

[JAZZCNC]

We going there again?

Nope.!! . . .but your talking shite again so it's very tempting.

[Chaz]

Nope.!! . . .but your talking shite again so it's very tempting.

OK cool - I like the 'again' part. There was no shit in our previous coming together, not from my side, only the truth. I stopped - could have provided a lot more detail to question some of your responses but I thought better of it.

You just love confrontation and drama, don't you?

[Chaz]

Nick, before this descends into a shitfest, take whatever info you think is appropriate and see what works for yourself and your setup. Clearly some of us have different experiences and outcomes. Id prefer not for this thread to be ruined too.

The response could have been different but it wasnt. So will leave it at that. Feel free to call me if you want, you have my number.

[Nick]

Thank you both for the advice. I have had a lot more success. I bought an array of end mills from shop apt. I have also been using single flute end mills that I saw used on a Datron machine, these seem to work quite well, there is a bit of chatter and they make funny sounds on ramping. I've even tried filming this.

https://youtu.be/wAAnl7nuGu8

https://www.youtube.com/watch?v=Ozca...ature=youtu.be

I have noticed that my setup isn't as rigid as I thought, there is nearly negligible backlash if I move the table with no force but if I apply some force to the table I can move it about 0.05mm in x and y direction, I can get it to almost 0.1 if I really lean. I'm not sure where this is coming from, I think it might be the ballscrews / x-axis belt, i'm not sure how to isolate this? I know a lot of people were having issues with the ball screw BK12 mount bearings.

I have ordered some metal for the enclosure, I was going to try and bend sheet metal, but I've abandoned this idea and I am going to weld a frame and then bolt/weld sheet metal onto it. Not sure what to do about the doors yet, any ideas?

[Washout]

there is a bit of chatter and they make funny sounds on ramping. I've even tried filming this.

Is the "funny" sound you're hearing on ramp down for the pockets, that kind of crunchy gravel sound as the tool gets below a certain point? If so I'd wager that is the tool re-cutting chips which your air is not clearing out of the pocket. I've added a second air nozzle to my machine recently to try and combat some of this, as chips love to lie in the lee of pocket walls and hide from that airstream.

Hope that helps.

Chris

[JAZZCNC]

100% it's re-cutting chips when spiraling down, you need lots more air to blow them out.

[Nick]

Update:

Enclosure nearly done, the design I came up with was really stupid, it weighs loads and took forever. If I was to do it again I would used thicker sheet metal without a frame. Lots more work than I thought. I finally weighed the mill, comes out at about 700kg in total.

I changed the castors on the frame to support the weight and so I could level the frame, spent a lot of time deciding on these. Please ignore terrible welding.



Mill pan:


Mill on:


Sides on:



Next step is to put some polycarbonate windows in the sides and then finish painting, doors after...