Anyone mill curly maple?

[mc-motorsports]

So I make these banjo arm rests for my father using a retro CNC Bridgeport..

http://www.littlemountainmusic.com/banjo.htm

Currently, they are made from Corian, yes, the same thing Dupont sells and is most commonly used to make countertops... I was against if at first, but I have to say it makes for a nice finished product, but slightly brittle... But VERY colorful!

Anyway, now he wants some made out of curly maple, as in the wood (expensive stuff!). He has one board of tiger stripped curly maple and people begging for them. Problem is I realize that this job is much better suited for a CNC router or a high RPM milling spindle and I'm limited to 3000 RPM.

Anyone do any wood working on a lower RPM spindle that can give me any advice? Should be straight forward, 2 flute HSS endmills and play with the feedrates. I'm just wondering if there is something I'm totally over-looking seems how I've never done woodworking, I mostly cut steel and steel alloys, some aluminum and a little bit of plastic.

The wood will be drilled and bolted down to a production fixture that was made for the Corian version. My intentions as of right now is use all HSS tooling and pretty much the same programs/feeds/speeds...

What do you guys think?

[epineh]

Is it possible to clamp a small router to your machine ? I am thinking 3000rpm is a little slow. I have a friend that did a little woodwork with his milling machine and the job turned out OK but needed cleaning up as the finish wasn't the best.

Can you try out on a test piece of wood of about the same hardness/density ?

Cheers.

Russell.

[blackbeard52]

I agree with Russell, I saw an article in Home Machinist where someone designed a speed increaser made from a dremel. I dont think a dremel would hold up but the principle is the same. Make a router mount that would attach to the front of the spindle or side and use the CNC mechanics of the bridgeport to control the paths as usual.... a fast and easy setup.

Bob

[ger21]

HSS doesn't last long in wood. It's almost never used when routing wood. Can't help with the low rpm, but you may find that cut direction is critical, and may need to vary based on grain direction. If you find the edges tearing out, you may need to start with larger stock and keep the tool from breaking out of the edges of the stock.

[mc-motorsports]

I'm sure I could clamp a router to the quill, but honesly, I'm a little short on time to make one. Plus passing on the cost for the additional fixturing (router and router clamp), it would probably be cheaper to buy one. Anyone know where I can purchase something like this? Would have to be something a little beefier than a dremel though, would prefer something more along the lines of a semi commercial application.

The thing I'm worried about the most is there is a dovetail cut on the bottom, and it's pretty critical. Hmmm...

[Ben Olson]

I have machined walnut on my Haas VF3, using a 5/8 carbide end mill 45deg helix... at 7500 ( as fast as it will go ) it worked fine , aside from the clean up which was a PITA ( a machine full of walnut fluff ) clamping and cut direction are critical

[mc-motorsports]

Climb milling or conventional milling? Or are you talking more about with the grain vs. accross the grain?

Right now, the programs are set for mixed cutting direction, no problem on the Corian.