Monster undercutter advice

[Slixmix]

We have a chamber in here that requires a custom made Waukesha saw. It is a 20" dia. x 1.00 wide insert cutter. 28 total teeth 14 effective. It is for a 6061 chamber. The machine has 50 HP. Questions I have is where to start on feeds and speeds. I know on the intial pass that it's taking full width of the cutter we are going to have to step out radially to create the band. It is going into the part a total of 8.25 radially. How wide of a cut do any of you think I should start at? On the subsequent cuts (go's 6.10 deep) do you think I should still use some width cuts or take it all in one pass now that its not cutting full width. I was thinking of stepping down .50 (half the cutter) per pass in Z after the intial cut. Any advice will be helpful. Thanks.

[gcode]

I think I'd program this as a horizontal helix, spiraling into the cut.

That way the depth of cut would be constant

thoughout the whole cut.

1000 sfm and .004 ftp would be

191 rpm at 10.6 ipm.

How are you mounting this saw to the spindle?

[Psychomill]

Whoah Nick, that's hefty... Even with 50HP its going to be a doozy.... I thing I know the part you're talking about too...

 

I'd try as Gcode suggested. A spiral helix... blowing it out some with smaller undercutters would help too. To try and take it all with one tool would be a lot of cycle time. You doing this on the Kuraki or 1080? Watch your side load (depending on your hangout).

 

Something I like doing for this type of stuff is to helix out radially (pick a number... an inch lets say), then helix ramp in Z (if the cutter can cut in that direction). If you can't ramp, then just stepping down in Z before mover out more radially. Something to judge this on is to watch the amount of time and linear distance a tooth spends "in the cut" and under the shelf. Your load meters will let you know....

 

[3R!< W3NG3R]

just curious, how would you prog a horizontal helix?

[Psychomill]

Maybe Gcode's wording is throwing you off. It's referring to Spiral Out motion. In MC, under Pocket cycles, look at "True Spiral". Its that effect. You can use this or draw your own spirals to further control the start/finish points of the arcs as well as how the program takes the last sweep.

 

[Hardmill]

quote:

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under Pocket cycles, look at "True Spiral".

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G-codes got it. That would work best.

 

 

PEACE

[MattW]

I can't help, but I sure would like to see pictures of this, if the typical work around Livermore doesn't prohibit it.

[Mr.ZX]

Do you have to use a 1.0 wide cutter? a thinner tool will probably help reduce tool pressure.

[Slixmix]

This tool was ordered from the company we are making the part for. Thanks for all the input. I'll fill you in later as to how it go's. I'll try to take some pics also.