Titanium Machining

[EDMMACHINIST]

1) When. Titanium machining with coolant through tools ( Brother milling sales person says it need coolant through tools ,with flood coolants we can machine it( we are using a lot of 1 mm and. 0.5 mm diameter tools for titanium . Is it ok using non coolant tools ? Any comments regarding titanium machining ?
2) Lot of micro particles chips found in coolant tank and machine filter too( running titanium machining in Brother Speedio) Replaced filter ,clean tank .( after cleaning tank and replaced. filter I have added stainless steel mesh (40 size ) two layer and one filter pad and coolant paper(20 micron filter paper ) over coolant tray. Now do any one thinks CYCLONE FILTER may be best solution ? what else I can add for a better solution for filtration ?
3) We are using synergy 735 coolant for titanium machining production. Is it good ? any pro /cons ? what refractometer reading should i keep for titanium ?
4) our machine has a spindle cooling unit over our machine, but should we also need to add any coolant system ( because currently we running machine mostly 15000 RPM , titanium machining, coolant through tools machining ) if need a coolant cooling system which system is good ?
5) we planning to buy 80 more cnc milling machine- like a automation machine shop. so which is some nice centralized coolant system what pro and cons ? any recommendation ?
6) we cutting titanium plate and holding in a vaccum control table ( we made this vaccum control fixture in house , this plate has lot of grove in both side, and 4 open pocket (which open on second setting ) but then vaccum pressure getting los due to some vaccum leakage, Any tips and advices.
Please share your thoughts , ideas , tips , recommendation's
Thanks
Bilson

 

[mhajicek]

High pressure (1000PSI or better) TSC is beneficial, but not absolutely necessary. Better coolant filtration helps with tool life, but is not absolutely necessary.
For seven years I cut Ti bone plates on a 15,000 RPM Haas, using flood coolant for most of it, and it had sucky filtration. I could get five hours of life from a Helical 1/2" endmill doing dynamic roughing in Ti6Al4V-ELI at recommended parameters in a shrink fit holder with flood coolant (Hangsterfer's 5080). I used the spindle load sensor to alarm out when the tool was dull. The machine had no chiller of any kind, but was in a well temperature controlled environment.

For vacuum fixtures, replace the gasket once a day, or maybe even once per shift. If held compressed constantly it will temporarily lose elasticity. After letting it relax for a while you can probably reuse it a few times.