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15-01-2011 #1
What chipload should I use for a 3 flute 1mm endmill on aluminum, for slotting and for other cut widths.
I've been researching and found anything from 0.005mm to 0.02mm per tooth.
I really don't want to break this so I thought I'd ask here first...
Depth of cut I thought maybe 0.5mm for slotting, that might be a bit much though?
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Depends on flute length, spindle speeds and lubricant. What you got?
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15-01-2011 #3
Flute length is small, maybe 3mm. I only need to cut down a maximum of 1.4mm though. It's HSS.
Spindle speed, milling machine is 2150rpm...so very limited for this size of cutter. If I bolt the router spindle to the milling machine when I get it that will get 24000rpm - so still less than optimal but much better.
Lubricant would be me standing there with a brush and cutting fluid. Maybe WD40 as it's thinner so should get into the flutes more easily?Last edited by Jonathan; 15-01-2011 at 09:15 PM.
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15-01-2011 #4
If the cutter is a centre cutting type I would chain drill it. As a cutter that small is stronger radially than axially.
You also are not going round re cutting chips.
I would step all the way round 1mm then when you are done step 0.5mm then step 1mm again to cut out the webs.
You have then removed 90% of the waste and can then finish the slot.
For chip load 0.01 per tooth max.
But someone of your experience I thought you would have known this. Lol
Phil
Sent from my HTC Desire using Tapatalk
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15-01-2011 #5
The slots I'm cutting are 1.4mm wide and 1.3mm deep. (see my Gcode thread and look at timing pulleys program if you want to know exactly what's what...)
As a cutter that small is stronger radially than axially.
I think it's center cutting, not sure ... quite a big change to the code to do that but worth it I guess.
Where do you get the 0.01mm chipload number from, experience (if so good)? It's about the average value I found from checking various websites. I've used 0.025m chipload with 2mm 3 flute endmill successfully:
http://www.youtube.com/watch?v=p13LZ6IxmgY
(wrong title on that video!)
I may just grind a form tool to do this in the end, but it'll be nice to try it.
Experience! Only 7 years...much less than yourself I guess.
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15-01-2011 #6
Yeah axially sorry, luckily you knew what I meant.
As you increase cutter diameter you can push harder but with only one cutter I would play it safe.
When drilling you can go slightly higher chipload.
You could use a proper drill to rough out the slot maybe use a 1.2mm drill.
Then use the mill to thin the web and cleanup the walls.
I would go the full depth on the walls.
All my experience comes in an industrial environment over 20 years.
Phil
Sent from my HTC Desire using Tapatalk
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15-01-2011 #7
Higher chipload when drilling sounds logical due to being stronger axially, also I think the cutting edges on a drill are acute less acute angle so stronger ...
Anyway, I like the idea of 1.2mm drill since I've got plenty of carbide drills that size and one HSS. Due to the point angle on a drill I could actually squeeze in 1.8mm drill.
Time to add a drilling cycle I guess, more calculations...
Thanks for the advice.
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If you are cutting teeth, have you considered a small slitting saw in a wide arbor?
They may bend but they don't break (unless you have a Z whoopsy) :naughty:
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15-01-2011 #9
Yes I have considered that - it would be a lot faster. I've got a 1mm slitting saw that would do the trick.
The reason I've not done it is I've not got a tailstock for my rotary table and the pulley would have to stick out a fair distance for the slitting saw to clear the rotary table chuck. Maybe I'm being overly careful...
One nice thing is I can use almost the same gcode with slitting saw, just need to swap Y and Z axis.
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16-01-2011 #10All my experience comes in an industrial environment over 20 years.
looks like you missed a tooth on that pully?
parts for my 4th should turn up any day now :)
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