Depth of cut help in 6061

[New Job]

I need to rough out a mold cavity in 6061, and I am going to be using an 1" end mill with 2 (.375) round inserts. I normally run this tool @ 5000 rpm, 200IPM @ .025" D.O.C.. However this mold is going to run a lot longer than I normally like them too. My best option for speeding this up is to increase my D.O.C.

Any body have any recommendations on what they do in this situation.

[Guest]

I'd start out at

 

8,000 RPM 2,000 SFM

.1875 DOC 1.2 the Ø of insert

160IPM .01 CPT

 

IMO your .375 round insert is limiting you DOC options,

[New Job]

Boss has imposed an 80% of spindle MAX limit on me. I cannot program any faster than 6400 RPM. The insert is ad-defacto nauseum gonna stay as HIS choice for roughing inserts. Testing shows that the 5000 rpm @ 200 IPM runs good with .025 D.O.C.

 

Considering I'll be giving notice soon I guess I'll just leave it and let him fuss about the cycle time.

[Wally J]

Now really what is the use of having a 7500 or 10k spindle if you cant put the pedal to the metal?? ,, so to speak...

 

Best of luck to ya

 

Wally

[mold100]

I run a 3/4 2 flute sandvik with 2 inserts in alum molds everyday fortunately boss has no clue what I do has long as jobs are done. 8600 rpms, at 360imp at .065 depth of cut, I cut some pretty big vacuum cavities and very seldom does something take more than 2 hours to rough.IT IS LOUD THOUGH. If thats your only option I would def increase DOC< at .025 with a round insert you have a small chip load, I would go at least .06 to .075 and keep the coolant at the chip evac area as much as possible.

[Rick Curtis EastechInc.]

QUOTE

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Considering I'll be giving notice soon I guess I'll just leave it and let him fuss about the cycle time.

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s-up with that ?!

[terry5357]

quote:

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Considering I'll be giving notice soon I guess I'll just leave it and let him fuss about the cycle time.

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me too. Have salary gig, work 50-60 hrs per week, had food poisoning and missed 4 days, got my check and was docked for the 4 days. When I asked about it, I was told that he didn't have to pay me when off for med reasons. I said so the 50-60 hours a week for the past 9 months means nothing, answer "yep". I mentioned that I wanted to take a week of vacation in june, was told I had to complete full year before vacation is allowed 1 week for first 2 years, 2 weeks after 3 complete years. I asked him what his idea of salary was and he said taking an extra 30-45 minutes for lunch without anything being said. I stared job hunting as soon as I got home. I wanted to walk out when I got my docked check but the old lady wouldn't let me.

[Matthew Hajicek - Singularity]

Yep, salary no-good. Been there done that learned my lesson. Work 18 hours one day, miss day in the same week, get paid for four 8-hour days. Ick. I'm glad I'm on hourly.

[mold100]

Salary is what I prefer but I have had not had bad issues like that. Its a 2 way street and sounds like you guys that have been burned with it, your owners do not realize that.Gotta give some to get some.