Originally Posted by spaltiel  WOW it is beautiful.
What is the depth of the cut in each step?
Did you also mill edges of the block?
How often did you spray with the PAM?
I have like tons of questions regarding parameters and so..
I am really amazed with your result. It is very nice. |
Thanks!
I usually only spray once. For multiple tool changes or multi-program setups I'll clean off the swarf and re-PAM.
I really feel having as much horsepower available helps, and since your spindle is more powerful than mine you should be good.
My parameters?
For pocketing, rough pass, I used a Onsrud 1/4" spiral Super-"O"-flute bit, at 50ipm, .08"doc and 12krpm. I helix in at 3 degrees at 25ipm. I normally go at 72ipm at .1"doc but my router is on it's last legs, so I need it to last at least until the new machine is done! My stepover is only 13%, but I'm at a greater depth and higher feedrate. I leave about .02" on the walls and floor, and switch to a coated 2-flute endmill (from either Kodiak, SGS, or Niagara) for the finish pass. I always clean and re-PAM for the finish pass. Spray it on, and use a cheap brush to coat all surfaces.
For profiling, I use all the same parameters, except I cut the doc by half. You're at a disadvavntage without flood, since the chips want to stay in the groove, so you'll have to watch and use air, or a brush, and keep that path lubricated. Again, I leave about .020" for finishing. To mitigate deflection on the finish pass I'll use the same step down as the rough pass, then do a complete pass the full depth to clean the edge up.
As you can see in the pics, even though I machined the pieces on different days, they still line up almost perfectly.
One caveat about pocketing: I use OneCNC XR4 high speed toolpaths, which prevent full-width cuts and corner ploughing. This lessens the anount of deceleration into corners and curves, and puts a constant load on the tool. If you're not using high-speed toolpaths, I recommend helixing in and spiraling out, with as much depth as you can but decreasing the stepover. Also pre-drilling at all corners can keep the bit from burying, where too much of the bit is "surrounded."
02-22-2012, 06:58 AM
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