Need Help!- 20,000-30,000 Rpm CNC Milling Machines

[Ziggy33]

Hi All

I am working on a group of large aluminum extrusion projects. I'm looking at all options on choosing a production Machine. Quanity is going to be about 50,000-150,000 pcs per detail per year and I am looking at about 6-8 different details. The largest detail is 48" by 6" by 3" L*W*H.
I'm looking for a pallet changing machine with very high RPM I will be using a 10mm endmill to do 90% of the work. Note that the part has 2mm wall thickness. Most of the work is pockets and slots. I'm estimating the cycle time will be around 90sec to 120sec without pallet changer time.

Thanks

Ziggy

[mh454]

Originally Posted by Ziggy33 Hi All I am working on a group of large aluminum extrusion projects. I'm looking at all options on choosing a production Machine. Quanity is going to be about 50,000-150,000 pcs per detail per year and I am looking at about 6-8 different details. The largest detail is 48" by 6" by 3" L*W*H. I'm looking for a pallet changing machine with very high RPM I will be using a 10mm endmill to do 90% of the work. Note that the part has 2mm wall thickness. Most of the work is pockets and slots. I'm estimating the cycle time will be around 90sec to 120sec without pallet changer time. Thanks Ziggy

Do you have a tight budget you have to work with? You mentioned that the largest "detail" is 48". Do you need this much travel? With 90 sec to 120 sec cycle times, do you plan on swapping pallets after every cycle? If so the machine is going to spending most of its day changing pallets. A 15,000 RPM spindle with a 10mm endmill will produce almost 1,500 SFPM. Do you have to have more than that or would you just prefer? Once you go past 15,000 RPM you pay dearly for more RPM and it will limit your machine choices.

[Ziggy33]

Originally Posted by mh454 Do you have a tight budget you have to work with? You mentioned that the largest "detail" is 48". Do you need this much travel? With 90 sec to 120 sec cycle times, do you plan on swapping pallets after every cycle? If so the machine is going to spending most of its day changing pallets. A 15,000 RPM spindle with a 10mm endmill will produce almost 1,500 SFPM. Do you have to have more than that or would you just prefer? Once you go past 15,000 RPM you pay dearly for more RPM and it will limit your machine choices.

I have a 2006 vf6ss HAAS now with 12k spindle and midaco pallet changer. I'm running 1200 at .006 chip 3flt em. I'm looking for at least 15k, one other detail will be using a 6 mm em I will be making about 150,000 pcs on this detail If I run 1600 with .003 chip it should spin over 25k.
I need at least 42" of travel. I did say that the cycle time will be about 90-120 sec. a part but I plan on ganging up 4 parts at a time on a fixture so the cycle time shoud be around 6-8 mins or less.

[Scanfab]

How big are your small part dimensions? I make on our 4th axis machine over 50,000 complicated faceted parts per year in a Fadal 4020. About 20 tool changes to complete a part. I gang them up in a mandrel 64 parts at a time, designing 120 part mandrels now.