jspivey
Aluminum
- Joined
- Nov 18, 2018
- Location
- Southern Illinois
Hello all,
Let me start off by saying that I don't have much experience with extra long reach tools, so any and all advice is appreciated.
I have 18 parts with a .625" wide by 2.125" long by 2.5" deep pocket in them. Just to add some fun, the pocket finishes with a .125 corner radius. No, the design cannot be changed. The material is 4140 pre hard.
My first attempt at these pockets was using an Iscar ECI-4500-2.5COVF4. (1/2 endmill, 2.5LOC .015 corner radius). I've broken two of these endmills at this point and don't have any more on hand, or anything else long enough to try. On the second one, I had the chatter down quite a bit, but the endmill gave up not long into the pocket. Additionally, I realize that best case scenario is to rough out the pocket in steps with increasingly long endmills, however, that doesn't do me any good if I can't get the longest required EM to work. After roughing, I plan on going back in with a .25 endmill to finish the corners.
Toolpath was 3D adaptive clearing posted from Fusion 360.
Machine is a Dalian VDL-1000. CAT40, 8000 rpm spindle. No thru spindle coolant. Seems to be a good machine overall.
Cutting parameters when the second EM broke:
YG set screw holder. Relatively short gauge length.
Axial DOC: .25"
Radial DOC: .03"
Feed: .0015 IPT
Speed: 250 SFM (tried higher but chatter was terrible)
Entry method: 1/2" pre drilled hole
If currently waiting to hear back from the Iscar rep for our area to see what he can come up with.
I'd appreciate hearing what everybody's thoughts are as far as speeds, feeds, etc are. Thanks in advance.
Let me start off by saying that I don't have much experience with extra long reach tools, so any and all advice is appreciated.
I have 18 parts with a .625" wide by 2.125" long by 2.5" deep pocket in them. Just to add some fun, the pocket finishes with a .125 corner radius. No, the design cannot be changed. The material is 4140 pre hard.
My first attempt at these pockets was using an Iscar ECI-4500-2.5COVF4. (1/2 endmill, 2.5LOC .015 corner radius). I've broken two of these endmills at this point and don't have any more on hand, or anything else long enough to try. On the second one, I had the chatter down quite a bit, but the endmill gave up not long into the pocket. Additionally, I realize that best case scenario is to rough out the pocket in steps with increasingly long endmills, however, that doesn't do me any good if I can't get the longest required EM to work. After roughing, I plan on going back in with a .25 endmill to finish the corners.
Toolpath was 3D adaptive clearing posted from Fusion 360.
Machine is a Dalian VDL-1000. CAT40, 8000 rpm spindle. No thru spindle coolant. Seems to be a good machine overall.
Cutting parameters when the second EM broke:
YG set screw holder. Relatively short gauge length.
Axial DOC: .25"
Radial DOC: .03"
Feed: .0015 IPT
Speed: 250 SFM (tried higher but chatter was terrible)
Entry method: 1/2" pre drilled hole
If currently waiting to hear back from the Iscar rep for our area to see what he can come up with.
I'd appreciate hearing what everybody's thoughts are as far as speeds, feeds, etc are. Thanks in advance.