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Machinist Group of Northeast Indiana

Machinist Group of Northeast Indiana . Cutting Tool Theory Intro Speeds and Feeds July 8, 2014. What RPMs & IPM would you run?. Specifications (dry machining) Material: 1018 CRS Endmill : 5/8” diameter (.625) 8 flute High Speed Steel TiN Coating Amount to remove

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Machinist Group of Northeast Indiana

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  1. Machinist Group of Northeast Indiana Cutting Tool Theory Intro Speeds and Feeds July 8, 2014

  2. What RPMs & IPM would you run? • Specifications (dry machining) • Material: 1018 CRS • Endmill: • 5/8” diameter (.625) • 8 flute • High Speed Steel • TiN Coating • Amount to remove • “Z” total depth = 1.22” • “Y” total material = 3.5” • “X” total material = 6.25” Machine limits 7.5 horsepower 550-10,000 RPMs 200 IPM max (X&Y axis)

  3. Important Formulas(applies to any rotating tool) OR better known as

  4. Lathe (SandvikCoromant)

  5. Milling Machines(multi-flute cutters) Vf = n x Fz x Zn OR IPM = RPM x IPT x # of Flutes

  6. Milling (SandvikCoromant)

  7. Milling: Up or Down? • Conventional Milling (fights the rotation) • Aka: UP milling • Starts at ZERO chip thickness and progresses to MAX • In most materials, should only be used with machines with backlash • Climb Milling (acts like a wheel) • Aka: Down Milling • Starts at MAX chip thickness and progresses to ZERO • In most materials and set-ups, this is the best choice

  8. Face Milling

  9. Climb Milling Feed per Tooth Maximum chip thickness Working engagement average chip thickness

  10. Traditional Milling Engagement

  11. Radial Chip Thickness

  12. How does new concepts in metal cutting help us on smaller machines? • Specifications (dry machining) • Material: 1018 CRS • Endmill: • 5/8” diameter (.625) • 8 flute • High Speed Steel • TiN Coating • Amount to remove • “Z” total depth = 1.22” • “Y” total material = 3.5” • “X” total material = 6.25” Machine limits 7.5 horsepower 550-10,000 RPMs 200 IPM max (X&Y axis)

  13. What we ran at SA with our old tools • RPM = 2200 • IPM = 190 • 1.22 = “Z” depth of cut per pass • Total depth needed to finish part • .030 = “X” step over (radial width of cut)

  14. Results: • It took 208 passes to finish the part • 3 minutes 50 seconds: Total time to remove 27 in3 of steel • We actually changed our cutting to G00 (rapid) moves • Cutter looked like it was new when we were done • Part and tool was cool enough to touch at the completion of the material removal

  15. Good Reading: • Cutting Tool Engineering Magazine • “Limited Engagement” by Bill Kennedy • July 2011 / Volume 63 / Issue 7 • http://www.ctemag.com/aa_pages/2011/110705-Milling.html

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