Metal removal strategy in large aluminum fitting...

[kunfuzed]

Hey guys,

 

Got a large aluminum fitting roughly 24" x 82" we need to rough out on a weak machine (Haas VB-1 5x, Hsk 15k rpm spindle). Pretty worn out machine. 2" facemills usually cant handle more than .100 doc at 5000rpm/100ipm with maybe a 75% stepover.

 

What do you guys recommend for getting the metal out as far as cutter/toolpath? Roughly 2" to 3" deep pockets, some have 7" legs to get around. Feedmill?

 

 

Thanks!

[Matthew Hajicek - Singularity]

I'd say if your pockets are long and/or wide, use a feedmill. If they're tight, drill entries and plungemill.

[BrianP.]

What kind of face mills? We use Shearhogs fro AB Tools. Can get real aggressive. They are real free cutting. You can run the feed mills but I don't believe on that machine you get anywhere close to the recommended feeds and speeds for aluminum.

[Guest]

I agree with the plunge milling, especially on a machine tired.

 

The radial forces involved with aggressive long tool material removal are tough on the spindle, wherein the axial push on the thrust bearing, is better in most cases

 

I would seriously consider plunging out the rough stock

[crazy^millman]

Have you looked at HSS toolpath to remove this Material?

[Oscar R.]

High speed toolpaths. Seems like you have enough machine to make these work well for you.