Milling 6061 with X3, need help

[wwendorf]

I'll get there eventually. For now, 3400 works for prototyping.

Wade

[shanepeed]

ZrN coatings also work when machining aluminum. It helps to keep the aluminum from sticking to the tool. When I ran my shop I ran tools at highest rpm's available. Worked very well and I had good tool life.

[Bird_E]

I'm running an X3 with a 1/2HP VFD belt drive, typically run about 3200 RPM,
1/2" two flute HSS endmill cutting Alum, .030 DOC @ 35IP works good for pocketing / profile, Just using compressed air to clear chips. With no coolant much more then .030 DOC . chip welding becomes a real big problem.

OH, it vibrates like hell when it's plunging... no matter what feed!

Once the x/Y cut begins it sounds sweet.

I nice sharp quality cutter makes all the difference!

My Site:
http://www.rlberg.com

Bob

[dneisler]

Thanks for all the input guys, I got sick and have not had a chance to mess with it.

Bird E
What exactly are you using to get "X3 with a 1/2HP VFD belt drive, typically run about 3200 RPM," I am working on a belt drive and looking for motor upgrades.

[wwendorf]

Do a ramping cut of some sort instead of a straight down plunge cut. Or plunge at 1 ipm and you won't have as much of a vibration issue.

Wade

Originally Posted by Bird_E I'm running an X3 with a 1/2HP VFD belt drive, typically run about 3200 RPM, 1/2" two flute HSS endmill cutting Alum, .030 DOC @ 35IP works good for pocketing / profile, Just using compressed air to clear chips. With no coolant much more then .030 DOC . chip welding becomes a real big problem. OH, it vibrates like hell when it's plunging... no matter what feed! Once the x/Y cut begins it sounds sweet. I nice sharp quality cutter makes all the difference! My Site: http://www.rlberg.com Bob

[sergizmo]

Originally Posted by Bird_E I'm running an X3 with a 1/2HP VFD belt drive, typically run about 3200 RPM, 1/2" two flute HSS endmill cutting Alum, .030 DOC @ 35IP works good for pocketing / profile, Just using compressed air to clear chips. With no coolant much more then .030 DOC . chip welding becomes a real big problem. OH, it vibrates like hell when it's plunging... no matter what feed! Once the x/Y cut begins it sounds sweet. I nice sharp quality cutter makes all the difference! My Site: http://www.rlberg.com Bob

Bob,

You could try pre drilling your plunge holes. If the pocket is .5 deep drill to .49or so. Then at the final end mill plunge do so at 1 or 2 IPM.

Serge

[KTP]

On my Shizuoka bedmill, which is 6000 to 7000 lbs, I plunge with a half inch endmill at no more than 2IPM in aluminum. Endmills are not really meant for drilling, they are best at side cutting.

[dneisler]

Well I got to spend a little time as I finished up a project for someone to take a look. It appears my Y axis gib has worked it's way a little lose, so I am sure that is affecting my finish on Y axis cuts and viberation. I hope to get more time today to tighten it up and recheck some other things too. Will report back shortly.

[AirHog]

My X3 (Grizz) would cut just like you describe just a few days after i got it. I couldnt do any depth without a lot vibration, and the surface finish was horrible. I finally tracked it down to the spindle, the "C" nuts that hold the preload must have moved just a hair out.

After i cleaned it up (since it was out) and readjusted the preload, the finish went from the worst I've ever seen, to mirror like. I was also able to get huge DOC's again. Worth a shot.

[dneisler]

Good info, I already to need to replace my bearings I think, they make noises badly. So I will check all that when I open the spindle up sometime. Kinda scared to take that appart.

[skullworks]

Scared to take it apart...

OK. Get the set of instructions put togather by the fine folks at Arc Euro Trade. They explain everything in great detail with color pics.

I'm not going to link directly to the PDF, but it is right there on there X3 mill page.

I just wish there was a good US distributer that offered there level of prep service in the U.S.

[dneisler]

Not really scared but with my luck something always be wrong or go wrong. I don't have good luck at all. I have there PDF, it doesn't look to hard other than I don't have a press.