Tried one at 2500. Just awful.

Wish I had a Landis too to try. I'm getting so frustrated with this thread. I've tried just about everything I can think of short of freezing the part before machining. We have a crazy_millman I need a crazy_threadman's help[ on this one.

Hi guys, I'm trying to get a decent thread in 6063-t6 aluminum and I'm not being too successful. I'm getting torn threads. It's an M10 x 1.25 thread (pitch dia. = .358) I've used Kennametal top notch inserts and sandvik lay down inserts with RPM's of between 250 and 1000 (slower seems better). Varying depth of cuts and varying last cuts and varying spring/clen up passes. I've used soluble oil coolant and Oemeta hycut cutting oil. I'm going to try a ground finish Iscar threading tool now and may try WD30, kerosene or any other friggin liquid (might try diet coke next, but not my Anjeo rum) to try and get a smooth thread. Has anyone had success cutting this crap material? Help, please, help.

Larry, am I missing something? You say your minor diameter max is .1 undersize... is it still bigger than the minor Diameter minimum? If so, is'nt the thread on spec? Also, on an external thread, minor diameter max, is important, so there isn't interference with the internal minor diameter minimum.

Ron, I'll pass that info on to our mill guy as see how it does. Thanks.

I'm wondering where you guys would start at for speeds and feeds to cut a 4-40 internal thread with a single point thread milling cutter. Thanks in advance. Phil

Hey James, Welcome and greetings from north of the boarder. Victoria that is.

Jas, I'll have a look at those in the morning. Thanks

There it is Chris. So would I.

Brian, I believe the feed as posted is in degrees per minute so to keep your programmed feed rate mastercam converts feed as needed. I would use c-axis tool path/face contour to define your cutting information then go into misc values and under integers change Misc integer MI4 to a -1 ( Mill Cyc G107/G112 [0=OFF,1/-1=ON) that will allow the program to post using polar notching as stated above. This will give you more familiar code and feed rates. Hope this helps.

Thanks for all the ideas. If we get the machine I'll put some of them to the test. I think we'll know today if the boss pulls the trigger or not.

We've tried many combinations of speed and feed to no avail. These parts get polished and buffed to a mirror finish so we are limited in our finish feed rate.

Thanks Chris. We usually can deal with the roughing tools ok it's on long, fine feed finishing passes that the this chips will wrap around the bar. Often the problem is not chips in the part but on the bar or turning tool itself.

Ken, What would you consider hi pressure? 200, 300 or like 1000psi?

Are you cutting on the face of the part or on the O.D.? I would try using polar notching (G112 or G12.1) if your machine supports it. It will give much better results.

I am wondering if anyone on here has experience with running aluminum parts on a MTM. The area I'm interested in is how to make sure, on finishing cuts on id bores, you don't have any chip issues such as bird nests wrapping around the bar and causing problems. High pressure coolant? Special inserts. It's all about chip evacuation. Thanks.

I'm guessing there would be a revolt if after telling us for too many years to count that they would make it added cost. I hope that isn't their plan or many mouths that have been silently waiting will surely speak out in unison.

I always start by drilling to near depth and then I use full rad face grooving tools that I grind clearance on and cut it in stages. You can some times find face grooving holders that will work for your diameters. Clearance is always an issue.

I'm old and cranky and tired of waiting. I guess I soon won't have to worry about it though. With luck I'll retire in about 7 years. Right about the time MTM comes of age in Mcam.

Tyler, We paid up for maintenance once again but it took some doing. We are looking at new equipment that will require more than Mcam can give us at this time. Much more delay will see the boss man choosing another direction. It is what it is. Too bad someone can't make a commitment.

Chris, Thanks for the tip. When we finally load up X6 (I'm a little gun shy of this release) I'll give it a twirl. Any improvement in lathe is welcomed. I do agree with saipen for the most part though. We've been led on for way too long in regards to lathe to be overly excited with an improvement that should have come along with X2 at the latest. I can just hear the conversations now, "baby steps, baby steps."

Matt, could you get a custom tool ground to not only cut the chamfer but to skim across the top and side with maybe 1 or 2 degrees of clearance? Inside corners might be an issue.

Thanks, Chris. I'll be sure to let you and Martin know if we get the machine.

James, do you have any links that a guy could go to to get an idea of what it takes to travel down the robot path?