Milling cooling fins?

[brandon b]

I'm curious to see what your thoughts are on milling these fins.

 

These were done on a vertical mill with a wheel cutter. I don't know the feed or doc specs he used but it took all day. I'm curious to see how to speed this feature up.

 

 

The fins are spaced . 250 apart

1.75 deep

15 inches long

[Matthew Hajicek - Singularity]

What's the slot width?  If you can get a solid carbide or carbide tipped slitting saw in the right dimensions and run it with ample coolant you should be able to speed that up.

[tim_h]

Can you purchase extruded alum heat-sink stock ?

[Bob W.]

Get an indexable saw.  Each fin could probably be done in two passes (if the machine has some balls) and it would be done in less than 20 minutes.  These saws are over $1000 though.  How many of these are you going to make?  What kind of machine?  If you are making more than 3-4 of these the saw would pay for itself on the first part.

[Bob W.]

Actually it might be a tad narrow for an indexable saw, I was thinking .25" slot width.  Go with what Matt said.

[brandon b]

Slots are .250 wide.

 

This is a prototype that is in the process of being approved.

 

There is "supposed" to be around 1500 pcs.

 

Machine is fadal.

[brandon b]

What's the slot width? If you can get a solid carbide or carbide tipped slitting saw in the right dimensions and run it with ample coolant you should be able to speed that up.

That's what he used on this part.

 

 

I don't know the specs but it looked like he was running about .5 doc and around 5 or 10 ipm.

 

Just my guess as i was glancing from a distance.

[Bob W.]

I have a 3" Ingersol indexable saw and run it at 7500 rpm @ 300 ipm and it cuts like butter, on a Makino.  Not sure what you could get away with on a Fadal but one of those would pay for itself on the first 2-3 parts.  You would probably need a 5" saw.

[Bob W.]

for 1500 pieces, depending on the lead time i would seriously look into having an extrusion made.  You would come out miles ahead if the customer went ahead with it but if they walked away after 10 pieces you would be out $$$ for the tooling costs.

[Machineguy]

And a 5" saw WILL NOT FIT THE TOOL CHANGER !  You'll have to load that by hand. 

 

Id go with what Bob said. Look into a extrusion

[AMCNitro]

The extrusion would only work if the fins were across the hole part.  If the part is like the one on the pic, with fins on one end but not the other, then the extrusion solution wont work.  

[brandon b]

The extrusion would only work if the fins were across the hole part. If the part is like the one on the pic, with fins on one end but not the other, then the extrusion solution wont work.

that was my next question. Yes the fins only go half way. Just as in the picture

[brandon b]

And a 5" saw WILL NOT FIT THE TOOL CHANGER ! You'll have to load that by hand.

 

Id go with what Bob said. Look into a extrusion

on our fadals with the umbrella style toolchanger it will. Just can't have a tool next to it. So say it's tool 10. Just don't have a tool 9 or 11.

[Matthew Hajicek - Singularity]

The Haas I'm getting has settings for large and heavy tools, to keep the adjacent pockets open and toolchange more slowly.

[brandon b]

The Haas I'm getting has settings for large and heavy tools, to keep the adjacent pockets open and toolchange more slowly.

that sounds like a good feature

[taperlength]

Redesign it as a casting.  Like an air-cooled motorcycle head.

[brandon b]

It was before. They said it was too heavy and expensive.

[AMCNitro]

No need to reinvent the wheel, just do it as fast as you can with as little spending on tooling as you can and charge as much as you can...

[Matthew Hajicek - Singularity]

Do it on a table saw.  You'll be done in five minutes.

[AMCNitro]

Do it on a table saw.  You'll be done in five minutes.

Hahahahahahaha!!! 

[crazy^millman]

Get an old school Arbor style milling machine. Setup the blades to cut them all on one pass. Might take 1 hour a part, but you could cut them all in one pass to depth and not worry about deflection. That was the last new machine one company I worked for got. 1965 Machine is mint condition was going to put all the CNC Machines to shame. Hate to say it, but for a part like this it very well could.

[brandon b]

Get an old school Arbor style milling machine. Setup the blades to cut them all on one pass. Might take 1 hour a part, but you could cut them all in one pass to depth and not worry about deflection. That was the last new machine one company I worked for got. 1965 Machine is mint condition was going to put all the CNC Machines to shame. Hate to say it, but for a part like this it very well could.

ive been waiting all day for your input ron. Do you have any link to a setup like that? Thanks

[mkd]

am i the first to say planetary gear speeder head?

finish walls on each depth cut.

good for small quantities

 

 

biga$$ wheel cutter is fast and efficient for quantities but depends how the slot floor terminates; square or radius?

[Zoober]

ive been waiting all day for your input ron. Do you have any link to a setup like that? Thanks

It would be similar to this, with the spacers set to the fin spacing.

http://www.practicalmachinist.com/vb/cnc-machining/slotting-saw-long-arbor-stainless-maybe-295587/

[Eric@HorsepowerInc.]

Stagger tooth side milling cutter, use dynamic passes, done in minutes! Currently cutting parts using this method and very very fast and easy on tooling. FYI, our deal is 1/8 wide thru cut slot at over 1.25 dp. I'll post feeds/speeds when I get back in.