Get Bold. | | Seven roughing down to 0.5mm from the bottom 3.5 depth of cut leaving 0.25mm makes 7 passes. Use air or preferably coolant, so chips don't get recycled. You should be able to rough at least up to 150mm/min or even 200.
Take one pass all around taking off another 0.15mm leaving 0.1mm for the finish cut. Final pass at Z-25.1 or -25.2 at 30mm/min
If there are any sharp corners in the profile make sure you don't just stop moving in X then start moving in Y. Going around corners you need to keep a constant chip load so that the cutter keeps bending/deflecting the same amount, so the path around a sharp corner is an arc. If moving into a corner and backing out pause for about 1 second before backing out. The bending of the cutter has to catch up. If your 2 flute cutter is really thick and stiff in the middle you could even use 5mm DOC. 1/2 diam of cutter should be OK.
Plenty of Speed, Reasonable Feed, Flood coolant. The chips getting recycled is what will do the most damage. 3500 rpm x 0.025 chip x 2 flutes = 175.
Go for 250 if the vibration is OK. Keep the HEAD LOW, Gibs firm, Short Cutter. 3500rpm or more.
Once machine/cutter deflection equals chipload is when the chatter sets in as the cutting becomes unstable. Also you should be climb milling. If not climb milling you are guaranteed a S#!T finish. Cutting away from you the waste part should be on the left and the finished part on the right for a clockwise rotating cutter. That makes each chip cut from full load at the front of cut to nothing at the side of the cut and any swarf get eaten on the waste side.
__________________ Super X3. 3600rpm. Three ways to fix things: The right way, the other way, and maybe your way, which is possibly a faster wrong way. |