[goor]

Hi,

I'm in the process of getting an XYZ 1010VMC 4 Axis mill up and running with CAM. I'm testing it with GCode I export from SolidCAM. I just made a first component, and can see the process will work. Up to now we've been working in Shopmill on the machine on steel components.

So now I want to test HSM operations on aluminium (4"x4"x2" block). I have a carbide 10mm finishing endmill with 3 flutes and cutting length of 22mm. I'm thinking of roughing at a spin rate of 200m/min (6400 rpm - my maximum is 8000rpm on the machine), at a Feed of 0.06mm/tooth (1140mm/min). The step down will be 3mm.

I've already tested this tool with these settings, but at a step down of 2mm. Seemed to do a good job. Does this sound reasonable?

What is recommended for coolant on such work? Any info will be much appreciated.

Thanks,

Goor

[icecreamjones]

Sounds reasonable to me, actually depending on how rigid the setup is, it's kind of babying the aluminum (feed and speed). Also depends on the radial width of your cut.
I am usually not one to push it too hard but some other guy could double that in aluminum with a solid setup.

[goor]

Thanks icecreamjones,

The set up is quite rigid. The machine is a very heavy mill and I'm holding the component on a 6mm insert holder in a vice. Also have a 10mm insert holder to make it more rigid. Since I am roughing, the tool is cutting at full radial width... meaning that it's cutting it's diameter (10mm). I'm just wondering whether I should rough at my max rpm of 8000, and maybe up the feed? Just don't know how much I can go...

And is it necessary to flood coolant on aluminium with a carbide endmill like this example? The only options I have for coolant currently is flood and air. Although I can manually control amount of fluid at the nozzle before machining.

G

[icecreamjones]

You can cut aluminum dry as you want from an abrasiveness standpoint but it tends to gall up your cutter if you are roughing like that. So yeah, I would flood it with coolant!

You could definitely use the whole 8000 rpm, that's only 816 sfm (we use inches) and I bet you could use a cutter twice that diameter with 8000 rpm. You could probably use more feed, maybe 150% or so but just leave the step down alone since you are in a full radial cut I think.
These are the types of speeds/feeds I use on 6061 aluminum all the time.

[rowbare]

I googled your mill. That is a pretty big and rigid machine and you can push it way harder than that. Do a web search for feed and speed calculator. There are several online ones and they can help you get a good feel for what you can do.

A downloadable option is GWizard. It is currently free and has a pretty good feed and speed calculator. It is written by Bob Warfield, one of the members here: http://www.cnccookbook.com/GWizard/GWizardInstall.html

Download it and plug in some numbers and see what you get.

bob