Feed Mill Sparking

[cajahawa]

Hi guys, I just got a new Iscar feed mill 1.25 dia. I'm cutting durabar 80-60-03 2000 rpm @.035 depth of cut. I'm getting a lot of sparking. Does anyone know what I'm doing wrong? It seems like the cutter is dull only after a couple minutes. Thanks Wayne

[Murray Mold]

Your rpm could be too high. I have a 1" Feedmill running 1872rpm @178 IPM x .04 D.O.C. in 4140 HT and it ran 6 hours before rotating the inserts.

[cajahawa]

Thanks murraymold, I forgot to mention I'm running 120 i.p.m. I'll slow my spindle down.

[Zoober]

Try air blast if you have it. Helps a LOT! We get 3.5 hrs in cut with, 1.5 without in 4140

[cajahawa]

Thanks Robert, I'm actually trying to figure that out. I run 2 Mazaks one says it has air blast but I haven't had a chance to try it. The one I'm using is much newer but I can't find it in the manual. So I may try rigging something up. I did take murraymolds advice and slowed my spindle down and increased my feed.That helped a lot. I think another problem, may be that they didn't have the tool I ordered so I had to get a longer one. It's hanging out 4.12" So I'm thinking that may be causing a little excess chatter.

[Goldorak]

i run a 2in iscar feed mill hanging out 7in without problem in 4340ht run about 4 hours

 

i install a 3/8 air hose with a ball valve at 120 psi to blow the chip off the pocket

 

ear plug is a must !!!

[mold100]

you def want some air hooked up. In p-20 I can run a 2" feed mill 1400 rpms 120.ipm with a .05 doc i am not sure of run time because it roughs fast and the off to next tools, I can rough alot of cores and cav material before rotation.

[Mr. Dayshift]

We do not run anything sparking. We do cut many special purpose steels, heat treated stainless', and most tool steels. We don't run sparking RPM's. We seldom run dry. It's either wet, or wet with airblast.

 

Ceramic, now thats another process.

[Darren Long SPE]

Hey mate,

Can you check this link out

ISCAR Cutting Conditions

 

Quite Handy --- its also in Metric for those of you that need it

 

[Zoober]

Mr. Dayshift - Are you talking about feedmills wet?

I have had no luck running wet at all. Thermal cracking destroys inserts WAY before they wear out cutting dry or wif air.

Have yet to destroy an insert without coolant.

We have even run dry in Finkl DC, a difficult High chrome Moly H-13....

[Mr. Dayshift]

Yes Robert, wet. We get no thermal cracking here. You might be running a way higher cutting speed than us though too.