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IndustryArena Forum > MetalWorking Machines > Tormach Personal CNC Mill > Tormach 1100 S3 using Tormach 1.5" face mill....
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  1. #1

    Tormach 1100 S3 using Tormach 1.5" face mill....

    I am about to start working on a part that has a ton of roughing I need to do, and I was going to use the face mill.

    Gwizard:
    .125" DOC
    1.000" EWOC
    1296 RPM
    10.262 IPM

    or I bump it a notch...
    .125" DOC
    1.000" EWOC
    1372 RPM
    23.707 IPM

    Is that anywhere close?
    What does everyone else use?
    Donald

  2. #2
    Join Date
    Jul 2007
    Posts
    1602

    Re: Tormach 1100 S3 using Tormach 1.5" face mill....

    What material are you using? That is relevant when posting this type of question...

    If GWizard is suggesting the upper values, your chip thickness will be too great using the lower values. Your depth of cut seems high for a face mill that size on a 1.5 hp machine. Calculate for a DOC of about .050.

    Also at that speed, make sure you are in the Low range. You will have full HP available, in high range you are at about 1HP at that speed and your metal removal rate will suffer.

    bob

  3. #3
    Join Date
    Mar 2009
    Posts
    1863

    Re: Tormach 1100 S3 using Tormach 1.5" face mill....

    I have watched the depth of cut and feed rates people have posted that they got from GWizard, and they look to me like they would work quite well. IF YOU WERE WORKING ON A 20 HORSEPOWER MACHINE.

    I have been doing this long enough that I have a pretty good what speeds and feeds my PCNC 1100 Series II is capable of, and what I see here ain't gonna happen without doing some damage to your machine.

    Can you post a drawing of the part you're going to machine and the material it's made out of?
    You can buy GOOD PARTS or you can buy CHEAP PARTS, but you can't buy GOOD CHEAP PARTS.

  4. #4

    Re: Tormach 1100 S3 using Tormach 1.5" face mill....

    It is 6061 aluminum. Just a simple somewhat round part. I am using customer supplied material, which is bigger than what is needed so I have extra to remove.
    DOC and WOC are changeable, just trying to remove material quick.
    Donald

  5. #5
    Join Date
    Feb 2006
    Posts
    7063

    Re: Tormach 1100 S3 using Tormach 1.5" face mill....

    You'll do much better running high RPM, fast feed, and reduced DOC. I doubt you could run 0.125" DOC at 1" WOC, especially at such low RPM. I'd run wide open - 4500 RPM, 45 IPM with coolant. Start at 0.05" DOC, and increase until you hear the spindle load down. Or, reduce WOC to 1/2", and go deeper until it loads down. Your maximum MRR should be somewhere around 3 cu. in./min.

    Regards,
    Ray L.

  6. #6

    Re: Tormach 1100 S3 using Tormach 1.5" face mill....

    Wow, it is a little over 1 hr roughing time @ .125 DOC and 1.0 WOC.

    I was hoping I could keep that or do better. Any chance this would be faster using 1/2" rougher? I hate using roughers but I got lots of material to remove. Most I have pushed my Tormach with the 1/2" 3F rougher is .500" DOC and .100 WOC. It may do allot more, just not pushed.

    What do you guys think would be best?
    Donald

  7. #7
    Join Date
    Feb 2006
    Posts
    7063

    Re: Tormach 1100 S3 using Tormach 1.5" face mill....

    Take depth times width time feedrate. That gives you MRR, in cu. in./min.. Pick whatever parameters give you the highest MRR. Your proposed numbers put you down around 1.25 cu. in./min., while the machine is capable of around 3 cu. in./min. What I gave you will roughly double that, and you should be able to go deeper, and increase it until you hit the spindle power limit. It doesn't much matter what tool you use, your max MRR is limited by available spindle power. You can use a face mill or and endmill, but your max MRR will be the same.

    Regards,
    Ray L.

  8. #8
    Join Date
    Jun 2012
    Posts
    311

    Re: Tormach 1100 S3 using Tormach 1.5" face mill....

    I have found the 2flute 25mm center cutting insert endmill works great for maximum MMR on the 1100 S3. In 6061 or 2024 I run it at .100DOC, .700WOC, 2500RPM, 50IPM. Calculates to 3.5 cu. in/min. Yes that is .010/flute. The inserts made for aluminum cutting do just fine. The spindle load meter needle is near the top of the green. I cut the feed rate to 25IPM when feeding into the cut since the WOC will be greater, or use an arc for the approach path. I had a job a while back where each part started as 20lb and finished as 2.7lb. I was able to cut the total time per part from 8hr to 5hr compared to roughing with a 5/8 endmill.

  9. #9
    Join Date
    Jun 2006
    Posts
    3063

    Re: Tormach 1100 S3 using Tormach 1.5" face mill....

    Quote Originally Posted by Steve Seebold View Post
    I have watched the depth of cut and feed rates people have posted that they got from GWizard, and they look to me like they would work quite well. IF YOU WERE WORKING ON A 20 HORSEPOWER MACHINE.
    Steve - GWizard has a setting for the HP of your mill spindle and that will limit the feeds and speeds that it gives you for a given set of cut parameters.

    Mike

  10. #10

    Re: Tormach 1100 S3 using Tormach 1.5" face mill....

    Thanks for all the info guys. I have my Gwizard set to the Tormach profile which has the HP limit set, but some the numbers it gives me look crazy.

    I wish I had the load meter on mine...
    Donald

  11. #11
    Join Date
    Mar 2011
    Posts
    480

    Re: Tormach 1100 S3 using Tormach 1.5" face mill....

    Don't have an 1100, but have a 2hp spindle. I just purchased a 4 flute 2.5"x,45 degree face mill from Shars and run .025 doc x 2.25,3500 rpm at 100 IPM. Spindle load is around 50%. Leaves lines during roughing, but followed up with a finish cut at 15 IPM leaves a nice finish. That's in 6061.

  12. #12
    Join Date
    Mar 2009
    Posts
    1863

    Re: Tormach 1100 S3 using Tormach 1.5" face mill....

    I have learned over the years that I can remove more material at a high speed, high feed ow depth of cut than I can with a larger cutter at a lower speed, lower speed deeper depth of cut.

    For pocketing, I have said several times before, I would develop a hole pattern and plunge ruff using a 30 to 40 percent step over. You start that by drilling a starter hole, then switch to your end mill. You'll find it goes way faster.
    You can buy GOOD PARTS or you can buy CHEAP PARTS, but you can't buy GOOD CHEAP PARTS.

  13. #13
    Join Date
    Jan 2012
    Posts
    789

    Re: Tormach 1100 S3 using Tormach 1.5" face mill....

    The best MRR I get is with a SuperFly cutter. This is a good demo of it:
    https://www.youtube.com/watch?v=Y2Xa0PMHM1U

  14. #14
    Join Date
    Nov 2007
    Posts
    2151

    Re: Tormach 1100 S3 using Tormach 1.5" face mill....

    The books say to always start with stock as close to required part dimensions as possible.
    Might get the mrr your looking for with a band saw .

    md

  15. #15
    Join Date
    Dec 2008
    Posts
    740

    Re: Tormach 1100 S3 using Tormach 1.5" face mill....

    Quote Originally Posted by mountaindew View Post
    The books say to always start with stock as close to required part dimensions as possible.
    Might get the mrr your looking for with a band saw .

    md
    but what do your books tell you about standard stock sizes?

  16. #16

    Re: Tormach 1100 S3 using Tormach 1.5" face mill....

    If my saw was big enough believe me it would be cut down.

    Sent from my SM-N900V using Tapatalk
    Donald

  17. #17
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    Nov 2007
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    2151

    Re: Tormach 1100 S3 using Tormach 1.5" face mill....

    Quote Originally Posted by TurboStep View Post
    but what do your books tell you about standard stock sizes?
    Machine shop trade secrets stress these points and a few more.
    Start machine operations with stock as close to part size as possible.
    Use clean and Square Stock.
    Rough mill everything in one pass and finish in one pass. . " I would guess this does not apply well to cnc machines with limited rigidity and power"
    And this would be very hard to do with an extra inch of material .
    These books are some what dated and fall back on older methods with examples of manual bp mills not 20 hp cnc machines growling for an extra 5 min or 1.5 hp cnc mills growling an extra 45 minutes.

    I figured dneisler didn't want the extra swarf and would size it if possible and I was more or less not helping and just increasing my post count. oops
    md

  18. #18
    Join Date
    Apr 2015
    Posts
    26

    Re: Tormach 1100 S3 using Tormach 1.5" face mill....

    To the OP, what feeds and speeds did you end up using? I am looking for feeds and speeds for this 1.5" 4 flute face mill on the same material, 6061 Al:

    Face Mill - 38mm

    thanks

  19. #19
    Join Date
    Jun 2014
    Posts
    1777

    Re: Tormach 1100 S3 using Tormach 1.5" face mill....

    Quote Originally Posted by AUSTINMACHINING View Post
    Don't have an 1100, but have a 2hp spindle. I just purchased a 4 flute 2.5"x,45 degree face mill from Shars and run .025 doc x 2.25,3500 rpm at 100 IPM. Spindle load is around 50%. Leaves lines during roughing, but followed up with a finish cut at 15 IPM leaves a nice finish. That's in 6061.
    I have the same face mill, works great up to about .050 doc 2500 to 3500 rpm, I just use it to face off stock (full width of cutter). I have my mill trammed in X but Y leaves a bit to be desired, so for small parts this works fine to finish the surface flats.
    mike sr

  20. #20
    Join Date
    Dec 2013
    Posts
    290

    Re: Tormach 1100 S3 using Tormach 1.5" face mill....

    nycnc just did a video recently on a shear-hog facemill single insert cutter, the MRR was impressive. Being a single insert, you can keep your RPMS up where your Tormach is happy, and push it pretty hard.

    Shear-Hogs (Shank Style)

    - - - Updated - - -

    nycnc just did a video recently on a shear-hog facemill single insert cutter, the MRR was impressive. Being a single insert, you can keep your RPMS up where your Tormach is happy, and push it pretty hard.

    http://www.abtoolsinc.com/prod/shear-hogs-shank

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