That's surprisingly slow speed for that feed, but I guess that's the point of these tools!
I don't use a flat. The flat is optional when ordering, but I didn't plan for using it since I figured it would shatter(as my 1/4 did) well before any other issues(slipping) occurred.
The material is 6061, the TAS are 3 flute variable.
I started off with the feeds/speeds in John's video and worked from there to get the best sounding, chip making, and fastest removal I was comfortable with.
I was hoping for fast removal rate and a decent tool life. I haven't been disappointed so far.
That's surprisingly slow speed for that feed, but I guess that's the point of these tools!
I finally got around to making a video. Please ignore the areas that I still need to tweak my operations. However, about the 4:38 mark, the TAS gets to eat...
Last edited by TonyUFN; 05-14-2018 at 05:22 PM.
At 1" deep, I'd think you would have issues with chip evac. It's what I saw when I tried... the chips didn't clear as efficiently.
I've only run successfully at 0.8" doc, 0.08woc, 3750rpm, 50ipm successfully (approx 1.2" stickout).
Last night, I was experimenting with both-ways adaptive and clogged up all the flutes(same stick-out as my video making the same part, 1.65" deep). 0.65" doc, 0.08 woc, 3700 rpm, 45 ipm. chip-welding the TAS is a painful experience.
Sorry it took so long to reply. I just got a chance this weekend to run a test just like the one on NYCNC, but with the Accusize 1/2" 4FL.
https://www.amazon.com/AccusizeTools.../dp/B00VGR6EVK
Up to 5 MRR was a breeze, 6 MRR was a struggle. I was making cuts in 4" of 6061 at 0.25" and 0.50" DOC and 0.4" WOC. John's first cut was at 0.5" WOC, which I think was a mistake, because all of the later cuts appeared to be at 0.4" WOC. You can tell they weren't at 0.5" WOC like the first one. I also did conventional milling like he did, though I almost always do climb milling. I think he did 0.3" and 0.5" DOC, while I did 0.25" and 0.5", because doubling the DOC doubles the HP & MRR (the math is easier to follow).
RPM: 3000, WOC: 0.4", DOC: 0.25", Stickout: 1.25"
I did cuts at feed rates of 30 ipm (3 MRR), 40 ipm (4 MRR), 50 ipm (5 MRR) and 60 ipm (6 MRR). 60 ipm was a struggle. In fact I aborted half way through (didn't want to break the end mill). But 50 ipm was a piece of cake. 50 ipm = 1.07 hp, and 60 ipm = 1.28 hp (all of this is according to GWizard).
RPM: 3000, WOC: 0.4", DOC: 0.5", Stickout: 1.25"
I did cuts from 10 to 25 IPM (I didn't try 6 MRR again). Again, up through 25 ipm and 5 MRR was fine.
Normally, I run it between 2 and 4 MRR. I use it mostly for adaptive clearing, not long cuts like this test, and it just doesn't present the opportunity for such aggressive DOC/WOC, but it does fine up to 5 MRR. Also, it has a 1.25" LOC and I don't want it to deflect (or break). I was hesitant to push it all the way to 6 MRR like that, because it is a long end mill, but I guess it is also a thick end mill as well.
Finally, I measured the tool after all of the cuts, and I didn't see any pull out. I follow the procedures outlined by Tormach, and I also put grease on the (ER32) collet nut. I think the serrations on the flutes also help avoid pullout.
I also run it at 2500 and lower ipm late at nite to quiet it down.
Right now I am still prototyping a lot, so I don't know how well this end mill will hold up in production. It isn't a carbide, but it certainly holds up well for prototyping use. I started with carbides, and broke them because I din't know what I was doing. I think I know what I am doing now, but haven't had the need yet for a lot of carbide tooling, though I love the carbide 3FL finish mills from Tormach.
Great info. Thanks!
I've been using the ENCO 3 flute rougher and am on my last one. Been looking for a reasonably priced replacement.
Glad to see John has finally started playing with the Alu-Power endmills. Saw a video from him yesterday where he is going on about the mirror finish they can produce. Interestingly, the very first video of his I remember seeing was when he was still playing with his Taig in his apartment years ago and he was trying to get mirror finishes in aluminum.
Bob La Londe
http://www.YumaBassMan.com
One of the sweetest cutter designs I come across in a long time. I enjoy the finish and speed they can run at with low noise / silent cutting.
I keep a full set of yg1 1/8,1/4,3/8,1/2- 3 flute ticn coated in holders ready to go. Also a set for steel. Ordered and received a set of replacements about 2 weeks ago from sct. I also added a couple of the ball end mill sizes
Last edited by mountaindew; 05-09-2019 at 02:38 PM.