Insert cutters on Aluminum

[TheePres]

My prefered method of hogging alum. has always been to use biggest HSS cutter machine could handle and bulldoze the chips outta there. 3 months ago an Ingersoll rep convinced me to try/buy an insert cutter, and I never did get chance to try out this cutter until now. Well, of course sales guy is nowhere to be found now that i need his advice on how to use this thing.

Any advice you all could give on Feeds, speeds, DOC's, pocketing routines, etc...

Cutter is 1.25 Ingersoll Aluminator 0 degree, with .41 high inserts. Material is 7075 aprx 20x40x5.

[Rick Henrickson 65]

we run it 20000 rpm .21 doc .015 per tooth

[crazy^millman]

Well answer a couple question:

 

What type of Holder cat 40/cat 50?

What Horsepower do you have?

What Is the max feed rate you feel comfortable with?

What is the size of the Memory of the Machine?

What tpye of collant system?

[Rick Henrickson 65]

good point millman

the info I gave is what we run on our makino

20000, 1000 psi through spindle, 74 hp, feed up to 1400, tons of memory

[Guest CNC Apps Guy 1]

In all fairness, I'm pretty sure the Ingersoll guy moved. He's a class act and a very good technical guy. That being said, you can get the new Ingersoll guy's number from S&D Tool.

 

HSS??? That's SOOOOOOOOOOOOOOOO old school.

 

MAX RPM and 250 IPM @ .120 DOC is where I'd start not knowing anything about your machine. Those cutters kick serious arse. You did not go wrong buying that tool... TRUST ME!!!

[Rick Henrickson 65]

Hey James have you tested it against the Mitsubishi? we found the inserts last quite a bit longer and on thin walls it has much less cutter pressure. Can you give me some insight on the ingersoll we just started using them?

[crazy^millman]

Place I worked only used Ingersoll on Alum and they kicked some serious but. Contact your local guy and get them in there they are real good at looking at your application and getting you up to speed.

 

hth

[SLJ]

Been using the Iscar Heli-alu 1.25" 2 fl. with the 16mm inserts and their Click-Fit holder system. Because of a lack of spindle rpm, we only run it at 10k rpm, 228ipm, .25 depth, up to full slot width. This one reaches to 3.5" deep and has become our standard hogging tool. 40 taper, 30 horse, Vertical pallet machines.

[MLS]

Use the Iscar here too. 1.25 or 2.00 inch dia.

10-12 K 200- 250 ipm .250 depth full width.

 

Never seen an insert break or gall on these cutters. I think you can pretty much load to machine capacity and they can handle it.

[TheePres]

Machine Specs:

Cat-40 spindle, 8000 rpm, 15-20 hp

200 PSI coolant (non-spindle-thru).

 

Yes, i agree, my outdated Old School methods won't work on these little toys

Did not mean to infer Ingersoll guy skipped on me, Im sure he will be very helpful once i get him in here. Will start with numbers you all suggested and, and hopefully be cutting New School style soon.

 

Thanks All.

 

P.S. Running of Fanuc 0M datacard, and would be thrilled at say 300-400 IPM.

[SLJ]

Theepres, we run that same Iscar cutter on a couple of older machines at 6000rpm, 128ipm, with .25depth up to full slot. Also cat 40, but 20hp, and 7500 rpm max. giv your new cutter a tryout!

[Tinhman]

cat-50,15000 Spindle and 40Hp Hoz. machine.

3" insert cutter with 3 flutes.

I'am doing .16 doc, 10000RPM and 550.IPM reach 5.5" depth ( it is about 7853 SFM) all day long, smoke the whole shop.