small ribs

[travis meyer]

has anybody ever had any luck cutting small ribs in p-20.

i've got to cut a lot of ribs that are .085 wide and .100 deep in a mold i would like to rough them out with a .0625 flat if any one has any recamendations on feeds and speeds it would be aprecated

 

thanks travis

[Hardmill]

Tesco or Osg cutters will do the trick.

Tesco makes a nice 2 flute tialn coated mill 1.5mm

that would work great for this.

You'll wanna start @ about 800-900sfm(if ya got the RPM)

and .0005 chip load. Use contour ramp air only (no coolant.

 

 

PEACE

[Joel Walker]

With details that small I think you have to worry the most about deflection, I'd use about 50 sfm, Man you're gonna go thru alot of cutters.

 

Good Luck

[travis meyer]

did i figer this right (3.82x850)/.0625=51952rpm

[Hardmill]

Whats your max RPM ??

 

 

PEACE

[Guest]

yup.

 

 

Got a spindle that fast right?

 

AT 12,000RPM

 

.0005 CPT x 4 flutes = .004

.004 X 12000RPM = 24 IPM

[travis meyer]

15000 rpms dont make fun of me because its a hurco.

[Guest]

15,000 RPM

 

 

No seriously

 

 

 

OK, Im OK

 

 

 

You can make it work just have to adjust your feed accordingly

[travis meyer]

quote:

---

15000 rpms dont make fun of me because its a hurco.

---

wasent my recomendation

[Guest]

BTW, Mill Crasher, I am j/k with you.

 

Even my Mori's only go up to 14k

 

[travis meyer]

well i will give that a try and we will see how that dose in 49 hours thanks guys

[travis meyer]

quote:

---

BTW, Mill Crasher, I am j/k with you

---

i know

[Guest]

[Matt Berube at Ferron Mold]

I don't think you need this for the ribs in this discussion but another source for really nice rib tools is Velocity Tools

[Fred @ Slate Industries]

When I run a .188 flat

uncoated 4 flute Carbide endmill

in P-20

With these specs :.0007 cpt, 235sfm

The Calculator says 4775 rpm @ .013 ipm

I am taking .01 DOC.

The Cutter Chirps like crazy!

Do I have to take more then .01?

The formula says .3 0f the Dia.

 

If I double the rpm and feed rate

Then I can Double the DOC?

 

Baffled by the Formulas.

 

Tony

[Guest]

Tony, I hope you mean 13 IPM and not .013 IPM

 

On a .188Ø cutter I would start in the .06/.05 range on DOC, with a 45 to 55% engage radially. If I increase the speed and feed, I will as a rule of thumb, decrease the DOC but increase the radial step over.

[travis meyer]

.001 souldent be to much on the d.o.c. or is it?

any sugestions on 2 flute vs 4 flute on witch would be best for this aplcation

[Wet-Tech]

.001 should be ok. A two flute is usually best on small cutters because it is stronger and has more chip clearance. And I agree with hardmill Jabro and OSG both make very good small cutters. I use them all the time in hardened material down to .3mm dia.

[travis meyer]

we use garr cutters with tialn coating good or bad i dont know thats just what they give me

but i think it mite be a good time to try another brand that you guys have recomended

[travis meyer]

dose anybody else have problems with thermole exspansen in the spendle or x and y axis i can get .0015 on the spindle and x and y

[Matt Berube at Ferron Mold]

quote:

---

we use garr cutters with tialn coating good or bad i dont know thats just what they give me

---

We like Garr. Seems like premium tooling.

 

quote:

---

dose anybody else have problems with thermole exspansen

---

We idle our Fadal @3000 RPM 24/7 to keep thermal growth in check.

 

I bet the majority of machines out there grow .0015 or more from cold to hot.

[moldy]

Most of the machines I've seen, grow in the y axis when they warm up. Also there is some growth in the z spindle. I like too rough out and then if necesary reindicate for close work. Sometime shutting down over lunch can cool a spindle off.

I always try to work close but mostly its a waste of time as .0015 seldom makes a difference in the long run.

 

Moldy...

[travis meyer]

i do a lot of long programs most of the time at night unatended and the biggest problem is when i have 4 to 5 differnt tools that all run different rpms from 2500 to 12000. by the time the last finish tool runs the block is not in center and its gouging i was just wondering if all mills were that way.

[Andrew Abken]

Mill Crasher

 

Well only the mills that have been crashed!

 

 

Just funnin ya, seriously though, we have haas mills here (ie cheap) and they will move .001 to .0015 inches from cold to warm.

 

That might not sound like much to some folks, but we build molds, and its a mile!

 

If I give our sinker department trodes that are .0015 off they come unpluged so to speak. And I dont blame them.

 

My motto "Indicate early, indicate often! or spend more money on the machine"

 

have fun!

Andrew

[Hardmill]

mill crasher,

Putting a good long dwell b4 each tool runs usually

takes care of growth in -Z-, Garr has some good tools

also you'll definetly a 2 flt or 3.

In these instances I almost always use contour ramp,

unless geo doesnt permit.

If you have any questions feel free to give me a call,

My cell is the 562-686-#### NO. on my website.

 

 

PEACE