First VMC - 05 VF-3SS with TR160

[ccjung]

Hi Everyone

I make aquarium and other lighting components (mostly 6061) and I have been slaving away for the past 2 years on my trusty little Tormach PCNC1100.

I've easily made 600 or so heatsinks, lighting fixtures, etc, all taking upwards of 4 hours a piece.

The bulk of my work is .125 slotting with .30 DOC. I've currently been running my 2FL Carbide endmills at 4500 RPM and 9 IPM with .150 ADOC.

What kind of feed speeds should I anticipate with a 12500 RPM machine?

I'm going to be getting an air turbine 65K air spindle at some point, but would like to know what I can expect once i get the machine.

Thanks in advance

Chris

[Matt@RFR]

I run 1/8" 2 flute carbide endmills at 12,000 RPM, 60 IPM, .1" deep in a full slot in 6061 with no problems at all. Use stub length endmills from a good brand name, lots of coolant and a decently rigid workpiece and you should be able to feed it faster than that. 60 IPM is just what I settled on for short run stuff because it's reliable.

[ccjung]

What are some good brands?

TIA

Chris

[lkenney]

iscar http://www.iscar.com/


and Swift Carb http://www.swiftcarb.com/

Good Luck

Lowell

[ccjung]

I've definately heard of iscar before. First time hearing about swiftcarb.

I have been ordering 2FL Niagara 1/8" carbide EMs. Once in a while i'll try some Helical end mills, but my tormach doesnt have the RPM for it.

Anyone have any suggestions on air spindles?

[L8Train]

The SGS S-Carb is a nice 3 flute for aluminum. I would max out the rpm at 12500 and run 60ipm+ at .125 DOC.
http://www.sgstool.com/products/high...ance.asp#scarb

[Matt@RFR]

I use Lakeshore Carbide ZRN coated 3 flute endmills for aluminum almost exclusively. Great product at a really good price.

[JohnJW]

Originally Posted by ccjung I've definately heard of iscar before. First time hearing about swiftcarb. I have been ordering 2FL Niagara 1/8" carbide EMs. Once in a while i'll try some Helical end mills, but my tormach doesnt have the RPM for it. Anyone have any suggestions on air spindles?

I saw Air Turbine at Westec and thought about getting it. There's also a recent article on MMS featuring another US made air spindle with variable rpm. While searching for that article I found another company

http://www.airturbinetools.com/
http://www.mmsonline.com/articles/milling-with-air
http://www.mmsonline.com/articles/ai...-speed-spindle

Now I wonder about how they differ?

[ccjung]

the airturbine model retails for around 3500-4000. I am getting the 60000 RPM one for my 1/8 needs.

[Delw]

Originally Posted by L8Train The SGS S-Carb is a nice 3 flute for aluminum. I would max out the rpm at 12500 and run 60ipm+ at .125 DOC. http://www.sgstool.com/products/high...ance.asp#scarb

Ive tried these and there not worth it. I get quite a bit of chatter on the 3/8" one.
I tried running it both in a collet and a endmill holder. same results.

my speeds are 12k at 50.0IPM depth of cut is .5 ( through a 1/2 plate) width of cut varies from .1 - full width, tried it at 100IPM and thought it was going to explode.

My Alum gar 3 flute endmill runs 100-150 ipm same depth fo cut and up to .8 for .750 thick plates with no noise and its smooth.
If it wasnt for running the Gar aluminum series I would have demanded they take the haas back the second day I had it.
even a 1/8 endmill 2 flute chattered on a .005 side cut and .320 depth of cut.

in the back of my mind I still think there is a problem with something in the head or z axis, they changed out spindles and while the 1st one was bad the second one is kinda picky as well on alum. so we had to try different tool holders and its just the haas.

My haas seems to be real picky on the cat holders and the type of endmill for alum. and I havent figured it out. Kenmetal holders so far are the only ones that work good enough in the haas.

my fadal can use junk cheap endmills and junk cat holders all day long and not get chatter and thats a 8500 rpms and 50.-75.0 IPM you don't hear it cut and its smooth. even using these feeds and speeds on the Haas give me the chatter with the exact same tool and holder just changing the pull stud so it fits the haas.

I had thought it was the pull stud mounting but I was told that is built into the spindle.