What face mill do u use???

[aRM]

   

(03-20-2015, 04:28 PM)PixMan Wrote: 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.

KEN
Things seemed to have fallen in place without very much ado.
So, (without perambulating too much on the outskirts of verbosity), we used to love that phrase in school, or getting into too much detail for our other readers, we will let these pics tell the story. Only thing is we hope we get the loading sequence right. So here goes.....
1. First cut at 1mm Depth, 650 RPM #2 setting on the potentiometer, conventional milling mode, no coolant as specified as well, note with beautiful Bronze coloured Chips.
2. Pic of Insert after first cut. Like new  !!!
3. Second cut at same Speed
4. 0.20mm Finish Cut also at 650 RPM
5. Note the colour difference of the Chips from the High Speed Second Cut
6. Difference at the Higher Speed Finish Cut with the same Feed achieving a much nicer finish
7. Job complete to ultimate satisfaction
8. Condition of Insert at completion
9. Insert given wipe over for better view

We can only say THANK YOU.
U and Dave have been the real stars of this show.
LORD BLESS
aRM