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We always check the threads to a thread gage. Had an operator that was suppose to run 10-32 thread and used M5 X .8 tap. It's close enough to the pitch that it wouldn't break but the thread cut over size. The only way it was caught was with the thread gage.
I say it's part dependent. Our lathe parts are very quick and easy basically a steel doughnut. So we program them at the machine it takes no time. Roughing can cycles are the best to use. Want to try more depth of cut, leave more or less stock for finish. these are very easy to change with roughing can cycles.
Face mill I would use a shear hog, for end mills I use MA Ford tuff cut AL endmill line. I haven't found an endmill that can come close. I have ran a 3/8 diameter endmill at 12,000 rpm 400 IPM 3/8's deep in 6061-T6 plate and get approximately 5,000 liner feet of cut from one endmill. I have tried many other brands of endmills but nothing has come close to this endmill.
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Sorry, no advice on the post... but I would like to see if anyone can beat your member number!
James or Cnc app guy can I think he is number 58.
At my last job we cut 100% aluminum. You need a good coolant to be able to cut at high rates. We were cutting around 400imp with a 3/8 end mill. If it wasn't for a good coolant we would have never be able to hit those numbers.
Here is some info i have on Kovar.
Carbon .02
Nickel 29.0
Iron Balance
Silicon .20
Manganese .3
Cobalt 17.0
Aluminum .10
Zirconium .1
Titanium .1
Phosphorus .025
Sulfur .025
Tensile 85,000
If I remember right this didn't machine to bad. It was a little gummy, I would use Carbide for just about everything. Just like Bob said make sure you don't rub, with the Nickel you want to be cutting.
Is your part scale at the right scale? Is your part center line on zero? How are you programing front of the part as part zero? If so the front of the part should be on zero in mastercam. The plane i would use would be D+,Z- in mastercam
On Haas machine Rigid needs to be turned on. How old is the machine? If it is a farely new machine you can turn rigid on but it's just a trial and will shut off at 50 hours of use.
Ether ajust your tailstock or cheat with A "U" in the program. If you are not comfortable with editing the program than i would go with the tailstock option.
Haas machines like most look ahead when running. Just because it stoppped on that line doesn't mean that is the problem. Read though the rest of your program to see if your problem is there.
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