SO3 Machining Aluminum

Discussion about Tooling and Fixtures. End Mills, Router Bits, Hold Downs, Fixtures, Etc.
Fablicator
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Re: SO3 Machining Aluminum

Post by Fablicator » Mon Sep 14, 2015 2:10 pm

Okinawanwinds wrote:congrats, and tell me how do you protect from flying broken end-mill bit?


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Haha, safety glasses and quick reflexes.

Luckily I haven't broken one yet.

Fablicator
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Re: SO3 Machining Aluminum

Post by Fablicator » Tue Sep 15, 2015 9:05 pm

MORE DATA!

Ran some stub 1/8in endmills at 40IPM .05 step over, and .032 depth of cut in 7075 AL. Seems to work nicely.

I ran some standard length ones at 20IPM, .05 stepover, and .032 depth successfully as well. the endmill length really does matter a lot for chatter.

Also ran a 1/4" chamfer mill at 20IPM with .05" stepover.

Once I stiffen the Z plate I suspect all these values will increase.

Finally got my first real part off the machine also after 3 tool changes and 30mins of machining. All the changes were made probing to the stock and using the homing switches as reference.
IMG_20150915_153351.jpg
IMG_20150915_153351.jpg (67.83 KiB) Viewed 1988 times
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IMG_20150915_155228.jpg (65.8 KiB) Viewed 1988 times

CastIrony
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Re: SO3 Machining Aluminum

Post by CastIrony » Tue Sep 15, 2015 9:29 pm

That's beautiful
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WillAdams
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Re: SO3 Machining Aluminum

Post by WillAdams » Tue Sep 15, 2015 9:29 pm

Do you have dust collection set up so as to save the chips and recycle them?
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Fablicator
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Re: SO3 Machining Aluminum

Post by Fablicator » Tue Sep 15, 2015 9:35 pm

WillAdams wrote:Do you have dust collection set up so as to save the chips and recycle them?
Not yet, had to get this thing done ASAP for work.

Spoil board threaded inserts and a dust shoe are next on my list.

Fablicator
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Re: SO3 Machining Aluminum

Post by Fablicator » Wed Sep 16, 2015 12:24 am

Video of the machining for the curious.

https://youtu.be/iOgS626gK1Y

twforeman
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Re: SO3 Machining Aluminum

Post by twforeman » Thu Sep 17, 2015 7:17 pm

Wow. 60ipm is impressive. Nice work!
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Fablicator
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Re: SO3 Machining Aluminum

Post by Fablicator » Tue Sep 22, 2015 3:00 am

Got to do a little more experimentation over the weekend.

I added (2) .625x1.25x7" long aluminum rectangles as stiffeners to the Y axis plate to reduce flex, which seems to help a lot with the chatter. It's still there, but I would say reduced about 60%

With the modification complete, I started trying to take deeper cuts. Currently my favorite strategy is .25" depth of cut, .025" stepover, and 60IPM feed. This makes nice long dagger shaped chips, and seems to cause the least chatter of all while still keeping a .5in^3/min material removal rate.

I wonder which is really better for tool wear, since both strategies technically make the same number of cuts.

https://www.youtube.com/watch?v=SOvgP6ScfrM

WillAdams
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Re: SO3 Machining Aluminum

Post by WillAdams » Tue Sep 22, 2015 10:49 am

Won’t the deeper cut and greater tool engagement increase tooling life since it spreads the wear over a larger area, rather than concentrating it at the tip?
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WillAdams
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Re: SO3 Machining Aluminum

Post by WillAdams » Tue Sep 22, 2015 12:51 pm

Fablicator wrote: I added (2) .625x1.25x7" long aluminum rectangles as stiffeners to the Y axis plate to reduce flex, which seems to help a lot with the chatter. It's still there, but I would say reduced about 60%
Making a new thread on this.

Here: http://www.shapeoko.com/forum/viewtopic.php?f=11&t=6892
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