Dear All : I would thank you in advance for your responses.. I am using CNC Router for Woodworking and engraving relief on Wood and MDF since 2 years, without any trouble. Now, recently I purchased new Router to engrave in Aluminum, but after loosing several tools even in roughing process - I did not get any results.
My machine is having a following specification
4.5 KW Air Cooling Spindle
Max RPM 18000
Mist Cooling System
(Using Kerosene as a coolant)
2500x1300x300 mm working area.
The first design I started is attached and its 600 x 600 x 6 mm in Size.
Aluminum I am using is extruded grade 6061.
The tool and tool path, I tried for rouging is
Endmill 3mm and 3.175mm and tried
2, 3 and 4 flute tool.
9000 RPM and 18000 RPM
with 0.2, 0.25 and 0.3mm Deep cut
with a 1.5 to 3mm stepover
and 600 to 2000 mm/min feed rate,
in combination with above all.
But after a while the tool gets broken and the chips are melted inside the flutes of the tool.
I would request you to please suggest me what would be the right way of doing this design in aluminum in the above size.