Re: [CAD_CAM_EDM_DRO] Resolution and surface finish

Jon,
I keep the chips out with air. Sometimes I use Kerosene, but mostly for drilling. Flooding is not possible with my machine. I
have a "mist" cooling deal (leur?) but haven't installed it yet.
The pocket I refered to was done 7 passes at .100" each leaving .020" on the walls. One finish pass at full depth climb cutting
to take the remaining.
I'm going to reprogram and cut another one this weekend. I'm going to leave only .005" and finish with a new 4 flute.
I also find that when profiling I use the uppermost of the flute possible because the bottom of most endmills is worn first. Of
course in a blind pocket sometimes this is not possible. I'm not in a position to run out and buy new cutters all the time. I love
carbide but can rarely justify the cost.
Thanks

Jon Elson wrote:

> 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
>
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