[Ahamay17]

What kind of MRR can be expected in aluminum 6061-T6? And what are you guys getting? Mine seems very low, no matter what combination I use the spindle begins to bog down drastically at anything over a MRR of 1.45 in^3 or power over HP/28%...these numbers are from HSMAdvisor

Ray

[AUSTINMACHINING]

I get 2.5 using 1/2" HSS 3 flute end mill in aluminum. Spindle load meter around 46%. Spindle speed will dip 100-200 rpm from 6000.

[SCzEngrgGroup]

What kind of MRR can be expected? And what are you guys getting? Mine seems very low, no matter what combination I use the spindle begins to bog down drastically at anything over a MRR of 1.45 in^3 or power over HP/28%...these numbers are from HSMAdvisor

Ray

Something is not right. I typically run 3-4 cu in/min in 6061., and that is a comfortable level, not at the limit. What RPM/feed/depth/width are you running? What material? What kind of tool?

Regards,
Ray L.

[AUSTINMACHINING]

Maybe we should share VFD settings ?. Can't imagine what else it could be. At lower rpm's mine will "flutter". Just assumed it was a Mach issue/unstable analog out to the VFD, but have not measured yet.

Sent from my SM-G900T using Tapatalk

[Ahamay17]

Something is not right. I typically run 3-4 cu in/min in 6061., and that is a comfortable level, not at the limit. What RPM/feed/depth/width are you running? What material? What kind of tool?

Regards,
Ray L.

I am currently running our production out of 1/2" 6061-T6 flat bar, cutting with a HTC solid carbide 3 flute 38* helix 1/4" dia with .750" loc and .950" stick out...I have the RPM set to 6000, feed rate at 23 ipm, doc .255", woc .250" - I just looked and during the cut the spindle speed drops to 5800 rpm and the load meter shows 43%, and if I ramp the feeds up any the spindle just continues bogging until it finally slows enough to trip the VFD and breaks the end mill... I can't break the same 1/4" end mill without bogging the spindle way down and the VFD shutting off first...

Our shop voltage is a high 240v, actual voltage is 258v and since the unit is rated at 220v we installed a boost/buck transformer and lowered the voltage at the mill to 221v, thinking it might be the issue I bypassed the boost/buck transformer and operated the mill at the 258v and got the same results so I put it back in line...

Ray

[SCzEngrgGroup]

I am currently running our production out of 1/2" 6061-T6 flat bar, cutting with a HTC solid carbide 3 flute 38* helix 1/4" dia with .750" loc and .950" stick out...I have the RPM set to 6000, feed rate at 23 ipm, doc .255", woc .250" - I just looked and during the cut the spindle speed drops to 5800 rpm and the load meter shows 43%, and if I ramp the feeds up any the spindle just continues bogging until it finally slows enough to trip the VFD and breaks the end mill... I can't break the same 1/4" end mill without bogging the spindle way down and the VFD shutting off first...

Our shop voltage is a high 240v, actual voltage is 258v and since the unit is rated at 220v we installed a boost/buck transformer and lowered the voltage at the mill to 221v, thinking it might be the issue I bypassed the boost/buck transformer and operated the mill at the 258v and got the same results so I put it back in line...

Ray

I can easily snap off a 1/2" endmill without hardly even slowing the spindle, so you have something VERY wrong. I'd suggest you contact Novakon, and have them send you the complete set of VFD settings, to verify how yours is setup. There has to be some major setting that is completely wrong. I'd be looking particularly at the motor setup (voltage, frequency, and current), as well as the torque boost settings. At 6K RPM, it should produce at legitimate 1-1.25HP or more.

Regards,
Ray L.

[kvom]

According to G-Wizard with your data plugged in, the MRR is 2.2 in^3 per min.

[SCzEngrgGroup]

According to G-Wizard with your data plugged in, the MRR is 2.2 in^3 per min.

No.

0.255 DOC * 0.250 WOC * 23 IPM = 1.47 cu. in./min.

But, that is the kind of ridiculous result that made me give up on G-Wizard long ago, and use HSMAdvisor instead....

Regards,
Ray L.

[Ahamay17]

Maybe we should share VFD settings ?. Can't imagine what else it could be. At lower rpm's mine will "flutter". Just assumed it was a Mach issue/unstable analog out to the VFD, but have not measured yet.

Sent from my SM-G900T using Tapatalk

By all means feel free to share any and all settings that would cause a low power output, as it is right now I am at a stand still waiting to here back from Novakon... My VFD is Sunfar C300A

Ray

[kvom]

Actually it was a fumble finger by me on the input. Corrected gives 1.466 :nono:

[Hirudin]

Here are the settings my 300A had at some point in time. Use at your own risk.

0.0	0
0.1	4
0.2	0.0
0.3	0000
0.4	0001
0.5	1
0.6	0000
0.7	0.0
0.8	200.0
0.9	----
0.10	0.5
0.11	5.0
0.12	0000
0.13	20.0
0.14	60.0
0.15	----
0.16	8.0
0.17	1110
0.18	0

1.0	0
1.1	7.0
1.2	0
1.3	50.00
1.4	220
1.5	0.0
1.6	0.0
1.7	0.0
1.8	0.0
1.9	0.0
1.10	0.0
1.11	50.0
1.12	0.0
1.13	----
1.14	0
1.15	220
1.16	50.00
1.17	6.40
1.18	1400
1.19	2.95
1.20	0
1.21	0001
1.22	0.30
1.23	0010
1.24	1.790
1.25	0.075
1.26	14.10
1.27	0.06
1.28	----
1.29	1.00
1.30	----

2.0	0.0
2.1	5.2
2.2	4.0
2.3	20.0
2.4	0.0
2.5	200.0
2.6	0000
2.7	0.10
2.8	0
2.9	0000
2.10	0.0
2.11	10.0
2.12	----

3.0	1
3.1	2
3.2	3
3.3	6
3.4	0
3.5	16
3.6	5.00
3.7	10.00
3.8	2.0
3.9	110
3.10	2.0
3.11	----
	 
4.0	0
4.1	0.50
4.2	0.0
4.3	0
4.4	3.00
4.5	0.1
4.6	0.0
4.7	50.0
4.8	0.50
4.9	0.50
4.10	10.00
4.11	160
4.12	80
4.13	110
4.14	2
4.15	----
4.16	0.0
4.17	5.0
4.18	5.0
4.19	5.0
4.20	5.0
4.21	5.0
4.22	5.0
4.23	10.00
4.24	350
4.25	60
4.26	0010
4.27	0.5
4.28	----

5.0	0000
5.1	35.00
5.2	15.00
5.3	3.00
5.4	20.00
5.5	25.00
5.6	30.00
5.7	35.00
5.8	40.00
5.9	10.0
5.10	10.0
5.11	10.0
5.12	10.0
5.13	10.0
5.14	10.0
5.15	10.0
5.16	10.0
5.17	0000
5.18	0000
5.19	0.0

6.0	----
6.1	0
6.2	2.0
6.3	1
6.4	1
6.5	0.0
6.6	0.0
6.7	0.0
6.8	0.0
6.9	1.00
6.10	1.00
6.11	1.00
6.12	3
6.13	1
6.14	1700
6.15	0
6.16	0
6.17	1000
6.18	100
6.19	****

7.0	1000
7.1	10.00
7.2	0.0
7.3	10.0
7.4	10.0
7.5	10.0
7.6	10.0
7.7	10.00
7.8	----

8.0	0020
8.1	0000
8.2	0.0
8.3	0.0
8.4	10.00
8.5	0.0
8.6	10.00
8.7	1.00
8.8	10.0
8.9	0.0
8.10	0.0
8.11	0.0
8.12	10.00
8.13	0.0
8.14	----

9.0	0014
9.1	0
9.2	5
9.3	0010
9.4	10.0
9.5	1.00
9.6	0
9.7	0.0

C.0	190
C.1	370
C.2	180
C.3	----
C.4	3333
C.5	0010
C.6	0000
C.7	0000
C.8	100
C.9	1.00
C.10	1.00
C.11	1.00
C.12	0
C.13	2017

Note that I suspect the value for setting 2.1 ("Input upper limit voltage") was set to 5.2 as a "fix" for some faulty component from the factory, I'm pretty sure this value should be set to 10.0 .
I also changed the values for 0.10 ("Acc time 1") and 0.11 ("Dec time 1"). I'm guessing these wouldn't have anything to do with your issue, so I wouldn't suggest changing them from what you have.
I also changed 0.8 ("The upper limit frequency") and 2.5 ("Frequency with the max setting"), but I didn't change them very much.

A short video I recorded a couple years ago... (phew, seems like so long ago!) This is with a 1/2" bit.
https://www.youtube.com/watch?v=_2D2uDARWRM
I'm sure the machine is capable of more, I don't think I tweaked anything other than the width of cut. (edit: actually, I might not have even messed with that. I was using SolidCAM at the time and the version I was using has some kind of automatic feeds and speeds generator built in.)

[AUSTINMACHINING]

Here's another example. 1/2" end mill. .05 stepover .5 deep if I remember right.

https://youtu.be/Vsb_SteomF8

[Ahamay17]

Here are the settings my 300A had at some point in time. Use at your own risk.

Note that I suspect the value for setting 2.1 ("Input upper limit voltage") was set to 5.2 as a "fix" for some faulty component from the factory, I'm pretty sure this value should be set to 10.0 .
I also changed the values for 0.10 ("Acc time 1") and 0.11 ("Dec time 1"). I'm guessing these wouldn't have anything to do with your issue, so I wouldn't suggest changing them from what you have.
I also changed 0.8 ("The upper limit frequency") and 2.5 ("Frequency with the max setting"), but I didn't change them very much.

Thanks for taking the time! I went through my settings and the only ones that were different were also ones you noted Acc time 1 - 0.10, mine was set to 2.0 and Decel time 1 - 0.11 mine also set to 2.0... I changed the accel time 1 value to match yours and I now have a entirely different machine...it seems my acceleration setting was so slow that a bog would happen faster then the acceleration could compensate?

Before I changed this setting it took a full 6 seconds for the spindle to go from stopped to 6000 rpm, with your setting it takes about 1-1/2 seconds... While cutting I was able to override the feeds from 23 ipm, (bogging would begin at 25 ipm with the old setting) all the way up to 40 ipm without any signs of bogging...which took my MRR from 1.45 in^3 to 2.45 in^3, and it feels like it has more..

My questions now...

Is the (Accel time 1) 0.10 value of 0.5 correct and or safe?

Those of you using HSMAdvisor, in the machine definition, what do you have as the Horse Power and Torque values? And on the Feeds and Speeds Adjustments, where do you typically have the sliders set at?

[Novakon]

The acceleration is good, but make sure it uses more time to decelerate since you don't have a braking resistor installed. I suggest a value of nothing less than 3 or 4. You don't want to back feed energy back into the power lines.. you will get some nasty errors at a minimum.

Regards,
John

[Ahamay17]

The acceleration is good, but make sure it uses more time to decelerate since you don't have a braking resistor installed. I suggest a value of nothing less than 3 or 4. You don't want to back feed energy back into the power lines.. you will get some nasty errors at a minimum.

Regards,
John

Got it, and thanks John!

Ray

[Hirudin]

That was a very welcome setting change for me as well! I didn't think it would have anything to do with the stalling, but I guess it makes sense.

The braking resistor is a really good upgrade.

[mklotz70]

I'd have to go back and look at my settings, but (provided the link works) this is what I ended up with.

Log in — Instagram

[keithmcelhinney]

I changed my accel value to .5 and big difference in startup. My deccel was set at 1. Wondering if that is why I have had so many issues with my bob...

Going to cut this weekend and see if it makes a difference. Would be pretty awesome if it does.

-Keith

The acceleration is good, but make sure it uses more time to decelerate since you don't have a braking resistor installed. I suggest a value of nothing less than 3 or 4. You don't want to back feed energy back into the power lines.. you will get some nasty errors at a minimum.

Regards,
John

[mklotz70]

I have my accel/deccel values set at .3 I do have a braking resistor.

I also had to lower the dwell setting in mach3.

Did the link work in my last post?

[Ahamay17]

I have my accel/deccel values set at .3 I do have a braking resistor.

I also had to lower the dwell setting in mach3.

Did the link work in my last post?

The link took me to an Instagram login page...I don't have Instagram so that is as far as I got...lol