03-20-2015, 04:28 PM
aRM,
I checked the parameters for annealed (soft condition) D2 tool steel. The recommendation is 375 surface feet per minute (approx. 115 m/min) so for that material you want to run closer to 826 rpm for your 44mm effective cutting diameter. Since you don't have that speed and it's risky to run higher, use the 650 rpm at the highest setting of the low range shown in the photo you had posted of available speeds.
That would put you at about 89 m/min cutting speed, very conservative. Feed rate should be around 590 mm/min, so do as DaveH suggests and calibrate by marking two lines 600 mm apart and note the position of the feed potentiometer when it takes one minute to travel that distance (or, 30 seconds for 300 mm travel.)
From there, the maximum width of cut is 44 mm with that cutter, so use about 40 mm. Now simply adjust the depth of cut to within what your 2HP spindle can do. Start at perhaps a 1mm depth of cut and see how much the machine does or doesn't protest. I'd guess that you could probably do about 1,5mm, maybe more.
You will likely check the inserts for wear after a few passes. This is where, if you set it as recommended, you will find a huge difference from what you were getting before. I'd venture that the inserts will barely look used. Cut dry at first, only use coolant or cutting oil as a last resort. Ping me here right away if you are having any problems and I'll do my best to troubleshoot via long distance.
I checked the parameters for annealed (soft condition) D2 tool steel. The recommendation is 375 surface feet per minute (approx. 115 m/min) so for that material you want to run closer to 826 rpm for your 44mm effective cutting diameter. Since you don't have that speed and it's risky to run higher, use the 650 rpm at the highest setting of the low range shown in the photo you had posted of available speeds.
That would put you at about 89 m/min cutting speed, very conservative. Feed rate should be around 590 mm/min, so do as DaveH suggests and calibrate by marking two lines 600 mm apart and note the position of the feed potentiometer when it takes one minute to travel that distance (or, 30 seconds for 300 mm travel.)
From there, the maximum width of cut is 44 mm with that cutter, so use about 40 mm. Now simply adjust the depth of cut to within what your 2HP spindle can do. Start at perhaps a 1mm depth of cut and see how much the machine does or doesn't protest. I'd guess that you could probably do about 1,5mm, maybe more.
You will likely check the inserts for wear after a few passes. This is where, if you set it as recommended, you will find a huge difference from what you were getting before. I'd venture that the inserts will barely look used. Cut dry at first, only use coolant or cutting oil as a last resort. Ping me here right away if you are having any problems and I'll do my best to troubleshoot via long distance.