Re: [CAD_CAM_EDM_DRO] Resolution and surface finish

Joe Vicars wrote:

> Material 6061-T6
> 1.5" flute length (sticking out of holder)
> Pocket Depth: .625"
> 1/2" endmill 2 flute, HSS, 2500rpm, 12ipm feed
> Climb cut, no coolant.

Is this an HSS end mill? You might try a 4-flute solid carbide
end mill. Any 4-flute is a little stiffer than a 2-flute, and the carbide
is remarkably more stiff than HSS. I have noticed an amazing difference
in 1/8" end mills, but the 1/2" is obviously not as flexible.
Also, an end mill with only 3/4" depth of cut will be stiffer than
one with longer depth of cut. You note no coolant, how do you keep
the chips from building up in the pocket? Recutting of chips is less
of a problem with climb milling, but it can still develop in a pocket
filled with chips, and will leave a ragged surface finish.

How are you machining this? Are you cutting it to full depth in one
or 2 passes? Do you have a finish pass to clean up the edges?
I generally leave .005 - .015" material at the outside edge and
then make one pass around the edge at full depth to clean up the
final surface.

Jon