Tips for profile cuts

[burbingus]

Hi guys,

I've been enjoying my Pulsar a lot, but I'm trying to get more efficient at using it - especially workholding and toolpath strategies. One thing that I've been having trouble with is profile cuts in aluminum. Some of the pieces I'm making require pretty small features to be cut with a profile operation. I was wondering if you guys had some good strategies for approaching profile cuts to decrease the machine time, especially with smaller mills - 0.125 OD and down.

Thanks!

Micah

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[AUSTINMACHINING]

Massive flood cooling helps with slotting profile cuts. I prefer to go fast and shallow cuts. Chip evacuation is critical. one clogged flute and snap.

[CL_MotoTech]

With smaller tools it's all about faster speeds. That 9k spindle will surely be useful for speeding those small tool feeds up.

The thing about small end mills though is that they are slow, it almost doesn't matter the machine, you have to spin them fast and then sit back and wait.

I also agree that fast and shallow is a good strategy. High tool engagement is asking for trouble with small tools.

[kvom]

I made an attachment to my machine to support a hi-speed spindle (30K max RPM). Really cuts down the time with smaller endmills or engraving bits.

[burbingus]

Hi guys,

Thanks for all the responses. I think in the short term, I'm going to try to find some better HSM strategies to remove the bulk of outside material with a larger end mill before cleaning it up with something smaller. In the long term, I'll get to work with an enclosure so I can start running coolant.

Micah