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21 Mar 2022 18:02:37 UTC
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Trying to make cylinder puzzle in aluminium
This is a 6mm 2-flute carbide end mill. Depth of cut is 0.15mm. I played with various feeds and speeds. RPM was mostly between 6000 and 12000, and horizontal feed rate was mostly between 500 and 1000 mm/min, with vertical feed rate between 100 and 200 mm/min. At one point I tried spraying some WD-40 as coolant.
Any tips on what I should improve?
My observations are:
- While the WD-40 does seem to improve the cut slightly at first, it causes the chips to stick to the work, which is a net negative in the long run.
- I think the RPM at the end was too low, which caused the end mill to take bites that are too big as the part starts to chatter, which is ultimately what broke it.
- The feed rate on plunging is too high and causes violent vibrations.
- The workholding is obviously not up to scratch. The part can vibrate too easily. It actually looks more rigid in the video than it does in real life.
...
https://www.youtube.com/watch?v=vwGdSfLLLjo
Any tips on what I should improve?
My observations are:
- While the WD-40 does seem to improve the cut slightly at first, it causes the chips to stick to the work, which is a net negative in the long run.
- I think the RPM at the end was too low, which caused the end mill to take bites that are too big as the part starts to chatter, which is ultimately what broke it.
- The feed rate on plunging is too high and causes violent vibrations.
- The workholding is obviously not up to scratch. The part can vibrate too easily. It actually looks more rigid in the video than it does in real life.
...
https://www.youtube.com/watch?v=vwGdSfLLLjo
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