Hi Guys;
I'm currently making a part for someone that has 1mm wide .1" deep channels milled into aluminum. I have a homemade CNC machine including the spindle.
I ran a few tests before setting on 7000 RPM (max) at 6 ipm feed .005 DOC (so 20 passes to get it as deep as needed). After about 45 minutes of cutting smoothly with air as chip removal / coolant (.070 deep) the endmill decide to snap.
I thought I'd ask before I broke my last 1mm endmill (more on the way) doing something wrong... What would you change? Is it just a function of run out breaking the tool in such a deep slot or are my numbers wrong? I noticed some welding of chips in the channel, is this my fault (too fast, not great enough chip removal)?
Thanks,
Cody