New milling motor Proxxon FBS 240/E upgrade to Kress 1050 FME-1

[Zynch175]

So I found some local guys doing a group buy, and I got in, so I ordered a 1,5kW spindle, since the 2,2kW are quite a bit over my budget.

[Chaz]

I had a Kress. Noisy as hell. Go for a smaller Chinese Watercooled spindle if you can.

[Neale]

And I wouldn't worry about going for the smaller spindle. I doubt that many home-built machines can fully load the bigger spindle and the main reason for choosing the larger size is they usually take ER20 collets which allow up to 1/2" cutter shanks.

[Chaz]

Indeed. The Kress is only rated at 1050 Watts. I think it will smoke before it delivers that type of output.

[Zynch175]

And I wouldn't worry about going for the smaller spindle. I doubt that many home-built machines can fully load the bigger spindle and the main reason for choosing the larger size is they usually take ER20 collets which allow up to 1/2" cutter shanks.

I went for the 1.5kW one, since the group buy has the 1.5kW or 2.2kW. And I decided that the new spindle is going on the new machine, that is in the process of designing (about 1000x1500 in size). It is going to be a modified frame of an embroidery machine, and the stepper motors and their drivers will also come from the machine. Once I get some drawings together I will post it to get an opinion on the design.

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[Davek0974]

And I wouldn't worry about going for the smaller spindle. I doubt that many home-built machines can fully load the bigger spindle and the main reason for choosing the larger size is they usually take ER20 collets which allow up to 1/2" cutter shanks.

I've got a 2.2kw WC spindle coming for a new build, what size cutter could these handle in aluminium??

I have read that torque drops badly at lower speeds but what is the usable range???

[Chaz]

I've got a 2.2kw WC spindle coming for a new build, what size cutter could these handle in aluminium??

I have read that torque drops badly at lower speeds but what is the usable range???

Typically 12 - 24K. Size of cutter all depends on width and depth of cut.

http://zero-divide.net/?page=fswizard get used to using this, it also tells you how much power you need.

[Davek0974]

Typically 12 - 24K. Size of cutter all depends on width and depth of cut.

http://zero-divide.net/?page=fswizard get used to using this, it also tells you how much power you need.

Thanks, looks like small cutters and solid carbide are the way forwards. HP does not really factor until you get up in the 10mm dia range and a 10mm carbide tool is quite spendy. But at that size machine rigidity would be a serious factor so conservatively I would guess that carbide cutters <5mm dia are the order of the day for aluminium.

Good calculator in that link BTW

[Chaz]

Thanks, looks like small cutters and solid carbide are the way forwards. HP does not really factor until you get up in the 10mm dia range and a 10mm carbide tool is quite spendy. But at that size machine rigidity would be a serious factor so conservatively I would guess that carbide cutters <5mm dia are the order of the day for aluminium.

Good calculator in that link BTW

Ye, very good as a starting point.

Stick to 2 flute for alu, my 'favorite' sizes are 8mm roughing, 6 and 10mm for finishing, 4mm for smaller if needed.

[JAZZCNC]

I've got a 2.2kw WC spindle coming for a new build, what size cutter could these handle in aluminium??

I have read that torque drops badly at lower speeds but what is the usable range???

The usable range is between 5000 and 24000 rpm if the VFD is setup properly. But yes torque does drop at lower speeds so does have limitations.
You can use the full cutter size range upto 13mm in aluminium but it will affect DOC and Feedrate. I cut lots of aluminium and find 8mm with 3 flutes is nice size that allows good DOC and feed rates. If used with trochiodal toolpaths the removal rate is brilliant and shifts large amount of chips.

My 2 most often used cutters are 8mm 3 flute rougher and 6mm 2 flute spiral flute for finishing. When ever possible I use Trochiodal toolpaths.