Dynamic Milling Experiment

[Alvaro Gil - Cimquest-inc.com]

I wanted to test out the new dynamic mill and see if it was all hype or a truly clever toolpath.

 

I must say I was extremely impressed with the results, I could not believe how awesome it worked!

 

I threw together a page with pictures and videos, check it out. I used High Speed tooling for frugality, but even at 4K RPM it moves pretty quick.

 

http://www.alvarogil.com/cadcam/mastercam/...namic_mill.html

 

We concluded that when doing deep pockets, the dynamic is much much much faster than a traditional pocket!

[Leigh @ Kodiak]

quote:

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We concluded that when doing deep pockets, the dynamic is much much much faster than a traditional pocket!

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You shouldn't have had to do a test to know this, but either way, welcome to the world of chip-thinning

 

Also, your site is not working for me

[Alvaro Gil - Cimquest-inc.com]

here you go, this has to work:

 

http://69.50.202.57/~alvaro/cadcam/masterc...namic_mill.html

[Tony35]

windows media player wont play the vid

what am i missing

[Alvaro Gil - Cimquest-inc.com]

I made them MP4s, I thought that was fairly generic, I guess not.

 

Format : MPEG-4

Codec ID : M4VP

 

--

 

I use the Full K-lite codec pack. It open almost everything except for techsmith videos...

http://www.free-codecs.com/K_Lite_Codec_Pack_download.htm

[Tony35]

that worked thank you

[Jimmy Wakeford from Barefoot CNC]

Awesome. We have been testing all the new highspeed paths, they are great. I have been working with tooling guys to get their input as well.

 

These paths will make customers more competetive. Bottom line.

Thanks for sharing.

[Alvaro Gil - Cimquest-inc.com]

One thing that amazed me was how cold the part was. The path really does make it possible to take a properly loaded cut and pull all those chips and heat away. Makes me want to cut everything dry!

 

Thats right Jimmy, I'm trying let them know they already have this awesome stuff and to just give it a try.

[Goldorak]

i am with Colin on this one

 

 

set step over at 15% stay at 4k rpm and set the feed rate to 400ipm , you should get the job done way under 1 minute

 

here the maths that i use (provide by ISCAR)

 

(tool dia - WOC) x WOC

TF= ______________________

 

tool radius

 

IPTxTF is your chip thickness

 

ipt/tf = compensate feedrate

 

so TF=.095

IPT=.005

compensate feedrate should be .052ipt

 

 

so finally .052 ipt x 2 flutes is .104ipr @4000rpm it's 416ipm

[Alvaro Gil - Cimquest-inc.com]

Awesome, I will try to lessen the step over next time. That particular machine maxes out at 157 IPM cutting federate, so I set the microlift for .02" and 150 ipm, but maybe if I lower the feed, it will move faster. I smell experiment #3.

 

Thanks for all the input, this is what I hopped for.

[Jimmy Wakeford from Barefoot CNC]

One of the tool guys I work with told me to step over %30 or 70%. Nothing in between, something bout chip removal... Not sure.

 

Alvaro we are doing seminars around the carolinas so people can see the paths run. It sounds so salesy when you tell them bout the cycle time reduction, they need to see it.

 

I am also doing a presentation at South Tec with Stewart-Haas Racing on Rapid Response Manufacturing, I hope alot of my customers walk out of there wanting to try this stuff.

 

Once a customer tries the first path they get hooked.

[Tony35]

quote:

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Once a programmer tries the first path they get hooked.

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fissed

 

once i tried it.... i want to apply it to every job i can

you cant beat the time savings

[Tim Johnson]

quote:

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Are you using the back feedrate and micro lift? If you put in values that are too high for a back feedrate, sometimes the machine/control can't slow down quickly enough and it bangs the tool into the material. This can break the tool, or cause wear pre-maturely.

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I have been getting tangency errors in Vericut;

 

"Warning: The tool positioned tangent to the stock material at a feed rate above the fastfeed threshold."

 

This doesn't seem to be a problem on our horizontals (yet) but is there something I can do to have the tool start at the cutting feed rate away from the part?

[Goldorak]

try to enlarge the toolpath radius ????

 

the feed change at the start of the entry radius

[Tim Johnson]

If you backplot the path in single step you can see the feed is still at back feedrate after the Toolpaths radius (50% on the part I'm looking at)has been completed. It appears to back feed right up to the removed material tangency. It also appears it's arcing with a G02 at back feed but backplot isn't telling me. Didn't X2 state the arc was cc or ccw?

[Alvaro Gil - Cimquest-inc.com]

I year ya Jimmy, that's why I threw the page up. It's hard to teach an old dog that new trick is actullay not a big marketing scam. Even I was shocked to see that it actually delivered!

[MattW]

-Semi hijack alert-

 

Seeing this is making me motivated to upgrade to X4. Seeing this also makes me think that maybe I should be approaching simple contours differently. I usually use 50% stepover, 50% depth until I get to the final contour. Should I consider going up to full flute length, reduced stepover, increased feed?....

 

I just opened up the 2D HS toolpaths, it looks like some of the strategies are there. Another problem I have found is what are the correct parameters for loops and such, it looks like there is some good info in this thread. Would those be good starting numbers?

[Tony35]

mattw

here is a link to a peel mill thread with a lot of good info

 

PEEL MILL

[MattW]

Well, this is the job I am working on right now, Nylon 6/6, about 1.5" tall. I am planning on profiling with a 1/2" 2fl hss end mill, 1" flute length. This is leaving .01 on the walls, should I just cut to 0? Haas MiniMill, 6000 rpm max. I have never cut faster than 150 ipm, some of the numbers I see being talked about are frightening, frankly, but also exciting.

 

These two parts are being cut out of a single block, I am going to do them in Delrin as well. I was going to use Peel Mill on the slots between the wells.

 

[Camaix]

Nice work Al.