1/8" 2 flute and "O" feed/speed/rpm

[diyengineer]

Would like to make a single .063" cut (all the way through) in 5052 aluminum sheet. For best tool life what ballpark numbers am i lookin at?

G wizard is telling me:

cut depth: .063"
cut width: .125"

RPM (24,000)
Feed rate: 36IPM
Surface speed: 785
chipload .0015

deflection .0012"
horsepower: .0227
MRR (CI) .2835

What is the proper chipload? Most likely bendable aluminum like 5052. I still need to hook up my koolmist system and air blaster.

Thanks for the help.

[Geof]

A chipload of 0.0015 for a 1/8" cutter seems a bit high. The rule of thumb that I use is 2% of the diameter for cutters above 1/2" and 1% or less for smaller cutters, a 1/8" cutter would fall into the "or less" region. I would not try greater than 0.001" and with 5052 I would keep well into the "or less" because this alloy is a bit gummy to machine.

[diyengineer]

recalculated it as you suggested .001" chipload.

says 24,000 rpm @ 24ipm now with a surface speed of 785.

I forgot to mention these are for a onsrud "O" flute cutter.

tool deflection of .0003"


I will have to try this on out. Hopefully kool mist will work well.

[DMF_TomB]

recalculated it as you suggested .001" chipload.

says 24,000 rpm @ 24ipm now with a surface speed of 785.

I forgot to mention these are for a onsrud "O" flute cutter.

tool deflection of .0003"

tool deflection based on end mill flute length and amount end mill is sticking out of the collet. is sticking of 2x more then normal then it is 2x2x2 less rigid
.
a stub length is around 1.5x dia in length, a regular length closer to 2-3x dia in length. in general if cutting through sheet material a stub length is better. ......also the sheet material should be held down with vacuum or double sided tape to plywood. i have seen partially cut sheet curl up as it is being cut causing end mill problems

[ger21]

Sounds to me like your feedrate is too low, and rpm too high. Find an Onsrud bit that matches what you're using, and compare to their charts. most seem to want .02-.03 chip load.
Aluminum Chipload Chart by Onsrud Cutter | | LMT Onsrud