Hello,
I have been reading for a while, but this is my first post. I have a question with regards to some parts made with my Sherline 5410 series mill.
I seemed to hit the limit of my operations the other day while cutting 7075-T6 aluminum.
DOC: 0.030
Spindle speed: ~5000 rpm (no tach, but theoretical 5500 rpm no-load)
E-mill: 1/8", 2-flute cobalt, standard-ish LOC.
Feed: 10 ipm
Chip load: .001 ipt
Cooling: Trico (Tri-Cool I think) synthetic mist
There appeared to be some "following errors" on the small radius curves. (as if the cutter was not accurately following the expected tool path) The larger radius corners looked fine but the overall finish was poor. (expected) There were no abnormal vibrations and the machine seemed happy, but the "following errors" on the parts were unacceptable. I do not get these errors when I reduce the feed rate.
Where could my problem be? Too high chip load? Cutter deflection? Have I made an error in my feed/speed calculations? Steppers can't keep up?
I ask this because I am concerned that my steppers may be at fault, and I have no reservation on upgrading the steppers or converting to servos. However, I understand that the feed limitations of Sherline spindle may make upgrading the steppers a waste. Is upgrading the steppers a waste on this machine?
I have some short LOC carbide 3 & 4 flute endmills on the way to hopefully rule out cutter deflection.
Any advice is highly appreciated!
Justin