I am milling some 6061 Aluminum with a 1/32 ball endmill.
I have so far busted 2 of them and I just ordered some 1/32 OSG Exocarb-BN ball endmill.
My main problem is my max spindle speed is 10,000
Does anyone have any suggestions for spindle speed, feed rate, and Depth of cut.
The cut I have to make is at the deepest is 0.015
Any help will be great,
I haven't run any mills that small but I have done some detail engraving with a 1/16 ball nose in 6061 Aluminum. My depth of cut was only about .010, and I too am limited by the 10,000 rpm spindle. I ran wide open at 10,000 rpm's and a chip load of about .0002 on my 2-flute ball-nosed end mill which figures out to be about 4.800 ipm. And plenty of flood coolant was used. You may have to slow your feed down a bit more since the mill is so small, maybe start around 3.00 to 3.50 ipm. Good luck.