RPM

[NEW2007]

I am making some aluminum mode on KOMO router.

As the manual book suggesting,the spinder RPM is

7000.The parts run on that high RPM,1/32" material is cut off for muti-pass or depth-cut.

Now the problem is the chips welding easily because of no coolant.Could somebody instruct if the RPM too large? (Cutting tool's 1/2" HSS 4 flute spiral)

[3R!< W3NG3R]

in my experiance, alum will always stick to cutters without coolant. You could try cutters made just for alum like the polished ones, but I always use coolant anyway. A mist aplicator might work for you too.

[#Rekd™]

Hi New2007,

 

I have no experience with a router but,

 

The rpm seems high for a high speed steel cutter, try about half of that. What feedrate are you using? What grade of Aluminum (3003)?

 

John Ford

[jeff]

Can you squirt it with WD-40?

That works great on Aluminum.

HTH

[GrahamWren]

hi,

 

i would say coolant is a must when machining ally due to the low melting temp it has, your spindle speed of 7000 is actually quite low, as eric says if you use cutters made for cutting ally then the speeds are very high.

 

try this

 

http://www.itc-ltd.co.uk/help01.pdf

 

 

but you really should be using coolant, any reason why your not?

[#Rekd™]

Hi Grraham,

 

I agree but he is using HSS not carbide.

 

The fpm for carbide is double that of HSS on most aluminum alloys.

 

rpm= (fpm x 3.82) / cutter dia

 

An oil mist or any thing would help.

 

John Ford

[MLS]

You can cut aluminum without coolant, but it depends on the alloy and temper. 6000-7000 series T condition it is possible, but softer than that I would say no way without at least a mist. In my experience.

 

Less flutes, carbide,as large a chipload and cutter relief as possible. Blow air on it to get the chips evacuated.

[#Rekd™]

Hi New2007,

 

My brother was working for Boeing and on their routers they were using single flute cutters.

 

John Ford

[NEW2007]

Hi,guy,

 

Thank you for your replies.I appreciate all of them.

I agree with Jford ,and will try single flute cutters.

The router is disigned for wood and plastic.There is not coolant system.The spinder limit rpm is 18000 for wood or plastics.We can machine very good aluminum mode.I still try to find good way to provent chip welding.

I don't have experiments on meltershop.Need your further instructions

 

NEW2007

[edmBosto]

A little kerosene works well also.

[ERIC14779]

Also you could try to rig up a blast of compressed air to cool and blow the chips away. My Quintax 5 axis has a Boelube mist lube system it makes a NIGHT and DAY diff.

[Chris Rizzo]

get rid of the 4 flute cutter for starters. try a 3 fluter first choice, or a 2 fluter 2nd choice. Your probably having an issue clearing chips out of the cut zone, thus some of the galling issues. Coolant is the "right" way, but you should be able to cut coolant-less with the right cutter and feeds and speeds. Look for a cutter designed for AL (high helix), possibly with a coating to reduce chance of galling. the best roughing gall-proof cutters i've found are Destiny brand, with the "black stealth" coating. Alternatly, you could stick with an uncoated cutter but with proper SHARP geo to increase shear and evacuate chip. I'm always trying new cutters, and thus far have found nothing better than Destiny, and MA Ford (138 3 flute series). With the right cutters, 7k rpm is still way under sfm for carbide and al.

 

hth