Why is this 15hp spindle so week?

[1320feet]

I have a Awea 1000 VMC that has a fanuc 0iMB control. The spindle is a 10000 rpm 15hp unit. I can only push my 3 inch Ingersol face mill at 45 ipm 3800 rpm .100 deep 2.3 wide in 6061. This shows 160% load. The spindle will start to loss rpm at 175%. I also slot in 6061 with a 1/2 inch 2 flute HSS end mill at 5300 rpm .500 deep by .500 wide at 65 ipm at 160% load.

I had a Cincinnati arrow 500 with a 7.5 hp 6000 rpm spindle that would run the same 3 inch face mill at 80ipm with the same rpm, depth and width as above and it showed 120% load. What should I be looking for?

[Greg Williams]

Power is torque x revs

 

You need to look at the torque curve to see where the sweet spot is

[Newbeeee™]

Is it a direct drive or a belt drive through toothed belts? Direct drive have less torque pro-rata as you have no 'gear' ratio.

[Machineguy]

Run a smaller Shell Mill, like 2.5:" dia max

For 40 taper machines, the standard max size was 3.0 dia for a shell mill.

 

Or decrease your stepover and depth of cut till you are at 100% for new inserts in the shell mill.

When it goes over, the inserst are getting dull or your taking to big a cut for the horsepower you have.

 

Machineguy