[Khalid]

This is the 2nd Part i machined out of SS316, 30mm thick plate.
Used Facing, Profiling, engraving and drilling operation.

I am getting gouging at smaller radius wall of the part.

Thank You Zafar for converting this into CNC . I can easily get 0.5mm deep cut on SS316 but my spindle motor is week for more than 0.5mm cut.
Here is the Video:
[ame="http://www.youtube.com/watch?v=wUttTrtwpvc&feature=g-upl&context=G2935e6bAUAAAAAAAAAA"]http://www.youtube.com/watch?v=wUttTrtwpvc&feature=g-upl&context=G2935e6bAUAAAAAAAAAA[/ame]

[Khalid]

Some Pictures of the finished product:

[Rene Nuñez Paz]

Hi Khalid
Nice work!! Congratullations..

By the way.
I post you a PM.
Could you help me?
Regards
Rene

[zafarsalam]

Wow, Khalid. You are already making parts on this mill. I thought you'll give it some break-in time. Did you do the engraving with the tool I made?

For the spindle stalling problem, I guess you are using too low frequency for the motor. Using SS tools perhaps. I'd suggest using carbide tools and high rpm's above 1500 or so. You'll need good collets and holders too. I'll get some for you on my next visit.

Zafar

This is the 2nd Part i machined out of SS316, 30mm thick plate.
Used Facing, Profiling, engraving and drilling operation.

I am getting gouging at smaller radius wall of the part.

Thank You Zafar for converting this into CNC . I can easily get 0.5mm deep cut on SS316 but my spindle motor is week for more than 0.5mm cut.
Here is the Video:
Milling SS316.flv - YouTube

[Khalid]

Wow, Khalid. You are already making parts on this mill. I thought you'll give it some break-in time. Did you do the engraving with the tool I made?

For the spindle stalling problem, I guess you are using too low frequency for the motor. Using SS tools perhaps. I'd suggest using carbide tools and high rpm's above 1500 or so. You'll need good collets and holders too. I'll get some for you on my next visit.

Zafar

Dear Zafar,
Thanks for the suggestion about increasing RPM of Spindle Motor and use of Carbide tool. I did that engraving with your machined tool...I have got slight depth in consequent engraving and that might be due to spindle warming.. So we made a rule of thumb as to start Spindle and wait for 5 minutes before pressing the Cycle Start..

I shall wait for the Collets and Holders and i hope you shall send us as early as possible as our TA of Plant begins from coming Monday so we need them most..

I am getting some tool gouging marks at smaller radius walls.. Whereas The bigger radius seems smooth at the entire place, only a small gouging mark at tool entry location at bigger radius..I have to change entry /exit parameters outside the part to get smooth finish..
Milling SS316 with DIY CNC.flv - YouTube

[skmetal7]

To get rid of that gouge mark, try to use a lead-in, lead-out if you can. It creates a small radius at the end of the tool path. Lead-outs at the bottom of a part like that will need clearance, otherwise you'll crash the tool into the left over stock. You could also use a ramp, instead of many depth-of-cut passes.

And I like that spindle light. Is it LED? I'm getting 2 of these: eBay - New & used electronics, cars, apparel, collectibles, sporting goods & more at low prices from China, and I hope they'll produce lots of light.

[zafarsalam]

Dear Zafar,
Thanks for the suggestion about increasing RPM of Spindle Motor and use of Carbide tool. I did that engraving with your machined tool...I have got slight depth in consequent engraving and that might be due to spindle warming.. So we made a rule of thumb as to start Spindle and wait for 5 minutes before pressing the Cycle Start..

I shall wait for the Collets and Holders and i hope you shall send us as early as possible as our TA of Plant begins from coming Monday so we need them most..

I am getting some tool gouging marks at smaller radius walls.. Whereas The bigger radius seems smooth at the entire place, only a small gouging mark at tool entry location at bigger radius..I have to change entry /exit parameters outside the part to get smooth finish..
Milling SS316 with DIY CNC.flv - YouTube

Khalid,

I would suggest using lead-in and lead-out to remove the gouge marks and also use rough and finish passes. I buy my tool holders and collets from KTD (PVT.) LIMITED you can contact them on the phone numbers at their website and inquire about the availability of ER40 collet holders and collets with MT5 shank. The ones I have are with BT40 shank. If you have adopters for BT40 then you can get these too. I'll be out of town this week. You can ask Mr. Nooruddin to buy the tool collets/holders for you and send them to you.

The engraving tool cutting again on the same depth of cut is due to your tool runout. It is not producing a smooth cut so it appears that it is cutting again with subsequent cuts. I had noticed it when I tested your machine with that tool. A good collet holder will take care of that.

Zafar

[Khalid]

To get rid of that gouge mark, try to use a lead-in, lead-out if you can. It creates a small radius at the end of the tool path. Lead-outs at the bottom of a part like that will need clearance, otherwise you'll crash the tool into the left over stock. You could also use a ramp, instead of many depth-of-cut passes.

And I like that spindle light. Is it LED? I'm getting 2 of these: eBay - New & used electronics, cars, apparel, collectibles, sporting goods & more at low prices from China, and I hope they'll produce lots of light.

Hi,
I used 3D Ramping for each passes for that part... but it is a good idea to use tangential lead-in and lead-out in my next oncoming part.....
Yes this is 10Watt LED Light (220VAC) i purchased for 14 US Dollars in local store... The light is too bright and awesome...

[zafarsalam]

I just watched the video. You are using climb milling. That will pull in the tool where the axes reverse direction (at the quadrants of circle) because of the backlash. Use conventional milling and also rough and finish passes. A 0.5 to 1 mm finish pass will produce good results. The feedrate is 20 ipm or mm/min?

Zafar

[Khalid]

I just watched the video. You are using climb milling. That will pull in the tool where the axes reverse direction (at the quadrants of circle) because of the backlash. Use conventional milling and also rough and finish passes. A 0.5 to 1 mm finish pass will produce good results. The feedrate is 20 ipm or mm/min?

Zafar

I am using Mixed Milling technique and i think your analyses about tool gouging is right. However i shall mill the same part later using Lead-in and Lead-out and will check the results... The feed rate was variable.. For 0.5mm cut we have feedrate 150mm/min whereas ramping till total tool engagement it was 27mm/min...

The engraving tool cutting again on the same depth of cut is due to your tool runout. It is not producing a smooth cut so it appears that it is cutting again with subsequent cuts. I had noticed it when I tested your machine with that tool. A good collet holder will take care of that.

The engraving toolpath was single pass... I think the tool/spindle warm-up made a slight 0.05mm difference in engraving depth....

For the tools i shall contact Mr.Noorudin,... He is really an expert in CNC Control system

[Khalid]

Nice work.

Thank You.

[Khalid]

Part was removed, deburred and polished.

[harryn]

Khalid, that is very nice work.

You are somewhere on project 10 or something, and I am just starting project 2. (project 1 turned out to be mostly learning)

Take care,

Harry

[louieatienza]

Nice work!

[diyengineer]

Here is the 90% completed machine

This is an awesome build!

[Khalid]

Thank you, here is the drilling video. 19.30mm drill on 60mm CS plate.
Today experimented the grooving. This is mock-up of tube sheet for weld qualification.
[ame=http://www.youtube.com/watch?v=smgMUNo7J4w&feature=g-upl]Drilling of Holes 60mm deep CS plate.AVI - YouTube[/ame]

[harryn]

That is very nice work to drill something deep. My brother and I did a 19mm diameter x nearly 80mm deep hole set once (but only once). Getting the chips out was challenging, and made me really realize why horizontal boring was invented.

If you ever get a chance to use a 7000 series Al, or one of the alloys with lead (Pb) you will never want to use 6000 series Al alloys again.

Unlike those dangerious, long, strings of Al that came from drilling in that video, they make very nice, short, broken chips.

Thanks for sharing.

Harry

[Khalid]

Hi Harry,
Thanks but this is carbon steel not Aluminum.

[Khalid]

Material : Carbon Steel
Thickness: 50mm
Cutter: 16mm Carbide
Depth of Cut/Pass: 1mm
milling Type: Climb
Spindle Speed: 1002 RPM
Blended Feed: 450 mm/minute
With Lead in and Lead out.

[ame=http://www.youtube.com/watch?v=g80vaQ5jd4Q&feature=g-upl]Machining of Bracket.flv - YouTube[/ame]