Originally Posted by
PROGRAMERDAVE
THE TOOLPATH CARIES A CONSTANT CHIPLOAD SO I CAN ONLY ASSUME IT THE BALL SCREWS. FOR 85% OF MY PART, THE CUT SOUNDS PERFECT.
You say you use Mastercam, but unless you are using something much much more expensive, I don't believe that you are getting a consistent cutting, chipload or not.
Chipload is only one way to look at the cutting. The other is engagement. Making a pass at .05" deep on a side is totally different than running into a corner or such where engagement goes from .05" to 3/4 cutter width. You may be cutting .006" per tooth, but you are doing it for a much much broader area of the end mill, requiring more power and making it more difficult to evacuate chips.
Look at your procedure at the point of chatter.
And, I have never had to replace a ballscrew in 15 years of cutting with a Haas. They may not be the most rigid machine out there, but they are no light weight.
Mike
Two Haas VF-2's, Haas HA5C, Haas HRT-9, Hardinge CHNC 1, Bother HS-300 Wire EDM, BobCAD V23, BobCAD V28