Surface Finish_2024 Aluminum.

[EazyE]

The majority of what we cut is plastics and I have three blocks of 2024 that need 12 tapered pockets 1.0 deep I have roughed them out with a .750 bull with .1875 r and rest milled the corners with a .375 ball and now finish with a .234 ball however I cannot seem to get a clean finish any speed/feed recommendations for this. Oh yeah I am leaving .020 material for finish..

 

Thanks. E

[3R!< W3NG3R]

What toolpath are you using?

What tolerance is it set to?

How far are the tools out of the holder?

what is the stepover/stepdown?

[EazyE]

Finish waterline.

Tolerance 2-1 .002

1" (depth of pockets are .960)

step down .007

 

Add: pocket walls range from 12° - 23°.

also using cabide ball for finish.

[EazyE]

Also the inside corner min rad is .250 thats why I went down to a .234 ball did not want pinch in the corners.

[3R!< W3NG3R]

I would tighten up the tolerance for the finish pass and use a .003" stepdown.

[EazyE]

Thanks Eric. looks allot better almost a mirror. what would you recmnd for speed/feed for finishing like this. I have 10000 rpm but machine gets a little jerky around 120-150 ipm.. so at 100. would be a good place but not sure of the rpm

[3R!< W3NG3R]

With alum, go as fast as you can IMO.

Feedrate is also determined by the machine, but 100 IPM sounds a bit fast for 10000 RPM. I usually feed at .002" or smaller per tooth for finishing.

[MotorCityMinion]

Cutting one way, CLIMB, instead of zigzag also helps with finishes.