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
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
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.
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
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.