Plug and Play 2.2kW Spindle --- Worth the upgrade?

[Joseph_Crowe_DIY]

Right now I'm using the Dewalt DW618 and I can get about 6.3 cu. inches/min for a Material Removal Rate for Baltic Birch Plywood. In other words I can cut 0.28" deep at 45 ipm with a 1/2" cutter. What MRR can I expect if I upgrade to the Plug n Play 2.2kW VFD spindle? Also, what cut depth can I expect to get? Can I assume at least 0.38" cut depth?

My machine is the Benchtop Pro 2'x3', and it's only a few weeks old.

Thanks,

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[skrap853]

You should be able to cut faster than 45IPM with a 2.25HP router. You might just need to calculate your speeds and feeds differently.

What RPM are you running the router at? How many flutes is the cutter?

Do you have NEMA 23 or 34 steppers on your Benchtop Pro?

[Joseph_Crowe_DIY]

You should be able to cut faster than 45IPM with a 2.25HP router. You might just need to calculate your speeds and feeds differently.

What RPM are you running the router at? How many flutes is the cutter?

Do you have NEMA 23 or 34 steppers on your Benchtop Pro?

I'm running the Dewalt full out...24,000 RPM. I have Nema 23. The cutter is the Whiteside Down Cut Spiral CNC Router Bit - 1/2" x 1".
This is baltic birch plywood...similar to this product...
https://www.woodworkerssource.com/bl...hen-to-use-it/

[skrap853]

That is a 0.001in chip load [chip load = feed rate / (RPM * number of flues)]. I generally cut baltic birch (which I buy at woodworkers source) at around 0.004 - 0.005in chip load using .25" spiral cutters (180IPM, 18,000RPM, 2 Flute spiral cutter). I generally plunge around half the diameter of the tool. For reference I have a CRP4896 PRO with NEMA 23's and a bosch 2.25HP router.

What is limiting your feed rate to 45IPM?

A spindle will run quieter, have a higher duty cycle, and last long in shops with continuous use. You should be able to increase you MRR with a spindle. Its worth will depend on what you are doing with your machine. As a hobby machine, or light production the NEMA 23s should pair nicely with the Dewalt router. The middle ground could be a cheaper spindle since the CRP PnP is $1700.00 before shipping. The 2.2kw spindles will require a 240V input to the VFD.

[ger21]

At 45ipm, you should be spinning it at 8,000 rpm. The bits probably really dull from all the heat it's generating.

You should easily be able to cut at 200 ipm @ 1/4" DOC and 15,000-18,000 rpm with the router you are using.

[Joseph_Crowe_DIY]

Thanks everybody I'm getting much better results running higher ipm and lower RPM. Can easily cut 100-150 ipm @ 8000 rpm with shallower depth of cuts, typically about 0.100"-0.150". Material is baltic birch plywood.

[skrap853]

Thanks everybody I'm getting much better results running higher ipm and lower RPM. Can easily cut 100-150 ipm @ 8000 rpm with shallower depth of cuts, typically about 0.100"-0.150". Material is baltic birch plywood.

In my opinion 150ipm @ 8000rpm is too high of a chip load:

chip load = feed rate / (RPM * number of flues) = 150ipm / (8000rpm * 2flutes) = 0.009375in

Woodworking routers are going to benefit from higher RPMs (more power). At 150ipm I'd think 15-18,000rpm would be better. As a general rule your depth of cut should be around half the diameter of the tool.

There is a lot of very useful information on the web about feeds and speeds. They will explain it better than I can. Speeds and feeds will impact material removal rate, surface finish, and tool life. The same cutter will have different speeds and feeds in the same material depending on the type of cut (contour, pocket, etc).