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IndustryArena Forum > MetalWorking > MetalWork Discussion > 3D SURFACING, YOUR BEST GUESS AT THIS PROB
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  1. #1
    Join Date
    Jul 2021
    Posts
    2

    Question 3D SURFACING, YOUR BEST GUESS AT THIS PROB

    So, I have successfully surfaced this with a 1/16th ball mill a couple times. All the other times is comes out like this photo attached. Really fuzzy and raspy on the flats.

    I am running it at MAX rpm for the mill (11,500. I know 20k or 30k would be better but aint got it.) and at about .0005 IPT chipload and .0035" stepover, attempted with both scallop and raster(parallel) toolpaths. Tried with both 2 and 4 flute endmills and only had success a couple times.

    A few questions I have are, given the 3d shapes, how much should I leave for the ball? I've been trying .003 before the final pass but should I do more? .010 or .012? Im stumped... Tried everything.. Maybe more chipload?

  2. #2
    Join Date
    Apr 2004
    Posts
    5728

    Re: 3D SURFACING, YOUR BEST GUESS AT THIS PROB

    It looks like you've chipped the end of your ball endmill.
    Andrew Werby
    Website

  3. #3
    Join Date
    Dec 2003
    Posts
    1206

    Re: 3D SURFACING, YOUR BEST GUESS AT THIS PROB

    How far was he tool projecting from the collet?

  4. #4
    Join Date
    Jul 2021
    Posts
    2

    Re: 3D SURFACING, YOUR BEST GUESS AT THIS PROB

    Well.. We're using a brand new ball mill every single time....

    The tool is choked up super close to the collet and its using a REGO PG tool holder with almost zero runout

  5. #5
    Join Date
    Mar 2009
    Posts
    1982

    Re: 3D SURFACING, YOUR BEST GUESS AT THIS PROB

    I would do an experiment.
    Anyway it is long story, requires thorough investigation.
    I would machine a piece of surface which goes ( always ? ) good, trying to destabilize the table with hand.
    It would be easy indication if table is stable. The next - almost the same destabilization attempt - headstock.
    It shows if headstock is stable.
    And, of course, I would check static tool runout. Must be less than 1 micron.
    The next - a bit bigger ball tool tip.
    These experiments will provide many information for discussions.

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