I've never milled this before. I'm quoting high freq diplexers, 1 x 2 x 8 inches, with tons, (no, really, TONS) of pockets (wave guides), close dia holes, and tolerances all around of ±.002 or less.

Where to start for:

Tooling?

SFPM?

How's the machinability? Is it stable? I'm a bit nervous. :D

'Rekd

Afther further review, it seems the Invar 36 and 36 FM (Free Machining) is like 36% nickel? WTF? That's Free Machining?!?!?! :eek:

It also seems it's used primarily for it's coeffecient of thermal expansion, (clocks, diplexers etc)

I also see suggestions to aneal it for stability. I will end up with about 75% or more material removal (pocketing out the wazoo), is this going to be an issue if I don't get it anealed?

Here's a pict of what it's gonna look like. The quantities could be in the hundreds, so I need to nail the cycle times/tooling charges.

:edit:
The pocketed area you see below is all toleranced at ±.002. :rolleyes:
:/edit:

TYIA

'Rekd

Originally posted by Rekd
~snip
I'm a bit nervous. :D

'Rekd

Maybe cut back on the coffee :D

Rekd,

Here's a link to Carpenter metals , some info on milling< not much.

Maybe you could call them and see if you can get a hold of "smart" app. engineer.

Or get your hands an a piece and see how it goes. Better to try it first hand then you will know.


http://crswnew.cartech.com/wnew/techarticles/TA00018.html

Originally posted by wms
Rekd,

Here's a link to Carpenter metals , some info on milling< not much.

Maybe you could call them and see if you can get a hold of "smart" app. engineer.

Or get your hands an a piece and see how it goes. Better to try it first hand then you will know.


http://crswnew.cartech.com/wnew/techarticles/TA00018.html

Thanks, wms. I can prolly talk a vendor into sampling me a piece for free. Good idea.

'Rekd

Sorry I did'nt get here sooner rekd'.
Looks like a nice project ya got there. How big(or small)
are the fillets vesus the depth of pockets?
If you can send me the file and i'll look at it.
I can point you in the right dir. for tools to.
BTW what type of machines are you using out there?

PEACE:D

Originally posted by hardmill
Sorry I did'nt get here sooner rekd'.
Looks like a nice project ya got there. How big(or small)
are the fillets vesus the depth of pockets?
If you can send me the file and i'll look at it.
I can point you in the right dir. for tools to.
BTW what type of machines are you using out there?

PEACE:D

Thanks hardmill. I figured you were prolly busy like a mofo or you'd have piped in long ago.

The doc to dia is about 6 to 1. I've done much worse in alum, brass, and some mild steels, but 36% nickel makes me a tad nervous going that deep. I'll be pre-drilling the corners out. I'll see if they gave me the database yet and send it over.

We're using all HAAS'. Hogging = bad :(

'Rekd

Reked the Haas will work just fine. I use to do invar in wave guides on Haas machines worked well..

Just so you know this stuff is abbrasive as heck.
Carbide and Cobolt are your freinds.

Originally posted by cadcam
...

Just so you know this stuff is abbrasive as heck.
Carbide and Cobolt are your freinds.

Is diamond coating cost effective? Prolly not, eh? I know it is on trodes (graphite) and things like G10-11, but I don't remember hearing anyone using it on metals.

'Rekd

I used that typ on cobolt.
I would stay with Carbide and go coded like Tiain.