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IndustryArena Forum > MetalWorking > MetalWork Discussion > problems breaking 1/16 2 flute endmills
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  1. #1
    Join Date
    May 2007
    Posts
    155

    problems breaking 1/16 2 flute endmills

    looking for chip load numbers for small endmills

    doing passes of .030 in alum casting

    not sure if I need to stay @ the .002 per tooth Or i can do .005

  2. #2
    Join Date
    Nov 2007
    Posts
    479
    you needs lots of rpm for small diameter end mills, as fast as the mill offers or can take, your chip load should be good and use coolant. Sounds like your flutes are getting clogged/welded.

  3. #3
    Join Date
    Feb 2007
    Posts
    498
    to take a .030 deep cut with 1/16 endmill you would need at least 10,000 rpms
    and a good flood of coolant,try smaller cuts with max rpm and faster feed rate,if your machine can only do 3-5000 rpms than you should stick with no more than .005 depth cut and 20-30 IPM

  4. #4
    Join Date
    Jun 2007
    Posts
    143
    GWizard says:

    @5100 RPM (the max my machine will do) 3 IPM and a chip load of .00029. No where near your .002. This could be why you are encountering breakage. I have also set the bit stick out to .375. If you have more stick out, you will need to go slower. I have had good luck using GWizard with small HSS end mills. If you can find a mill with a .25 stick out, the feed doubles to 6 IPM

    When the end mills get this small, deflection is the enemy and you best keep the deflection small.

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