High Feed Milling 4140 Steel
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- Опубліковано 13 вер 2024
- High Feed Milling Demo using Mil-Tec's High Feed Freedom Cutter
Material: 4140 Annealed
Mazak VCN510C Vertical Mill
Chips are a beautiful blue color
All the smoke you're seeing is hot chips hitting cold cutting oil
All these arm chair critics probably run Haas TM1's on aluminum all day. You bored a big freakin hole through some steel and it worked great by the looks of it. Good job
Derek Sommer a big freakin hole through some hard high carbon steel!
Thanks Derek! It worked great and have done it many times since.
I love the smell of hot pre hardened steel
Thanks Steamboat! The part was actually cool to the touch. The chips were pretty toasty though!
The idea is to let the heat leave with the chip and the part stays relatively cool, and the inserts don’t burn up prematurely.
i need 2 days to mill something like that at work, with a old deckel fp4 o.O
This is inspiring
WOW
If it were me I would add additional air blasting around the perimeter of that tool to get those chips out. Are you running air blast through the tool in this video? I would setup the machine to do that as well if you aren't already.
Very interesting videos, thank you, perhaps you guys could add more?
Thanks for watching our videos! We're working on some new ones including hard turning, and small hole drilling. Please subscribe to our channel to be notified when they're posted.
If the machine can handle just go buy a komet drill. They make them up to 82mm. We use a 2.0625 diameter drill to pound a hole through 6" of 304. Running it about 425rpm at .0035 a rev.
That's awesome troutbum86! What kind of horsepower do you have that runs that tool?
15ish hp and 180lbft
Mill better than drill
It was a relief when all the chips finally fell through the bottom of hole! How feasible would it be to drill holes (with through coolant) around the circumference with say 90% overlap and let the chunk pop down? Nice video :-)
+Brian Petersen wouldn't through coolant be useless then?
+Limosical Absolutely not. To release the chunk of steel, you need to drill all the holes through the entire block.
Brian Petersen isn't the idea of through coolant to have back pressure to push the chips back up into the flute to cool the tip and remove chips or have i been thinking about it wrong? you wouldn't pilot for a through coolant drill, because it's terrible for your drill, why doesn't the same apply to already having a hole 90% there.
+Brian Petersen Dropping out chucks of material has never worked well for us. All too often they way they drop causes the chuck to get wedged in place and then bind against the tool causing the tool/cutter to get destroyed.
+StarkIndustrial Good point. I'm glad you did tell about your personal experience for reasons not to use that approach.
What SFM are you using, chipload, etc?
Hell yeah
how hot was the cutter and raw stock? :D
Both were pretty warm, but that is a result of how long the cutter was engaged in the cut. If you were to simply face the top of the part, you would have not problem putting your hand on the part right away. Next time we do one of these types of videos I'll use our infrared thermometer to get a reading. Please subscribe to our channel to see future videos.
I can not imagine if he touched that cutting head with the finger 😱
Try catching one of those toasty chips
did you wrote a stop in the program or can you stop the cycle and start it again whenever you want if chips dont get out?
Thanks for asking! We wrote this program to machine 1.5" down and then retract to allow for chip removal. We can also put the machine in feed hold mode at any time and open the door to clear out the chips.
It's a Mazak, he can TPS and move from mid cut, flip inserts, blow chips and green button back to running. Nice vid, I love feed mills.
i could see that burning the tips out. theres just too many chips flying around in there.
id lift if every 10mm or so and clear it out myself
What sfm and fpt
Is there any other option than stop the machine to clear the chips?
Hi Felix! Additional air lines from the top and on the underside between the vices would be a big help. If this was done on a horizontal machining center, chip evacuation wouldn't be an issue.
Jonathan Wilkof thank you for the answer!
Through spindle air.
What's your downfeed per revolution / ramping angle? Feed per tooth & SFM?
Looked like .1 and 100 inchs
Whats the spindle size
would this tool fit a delicate spindles like on haas?
+Fischer977 A high feed mill is a great tool for lower power machines like a Haas. As with any machien tool you need to be careful about the cutter diameter you're running. The bigger the cutter, the more horse power you'll need, but because nearly all the cutting force is directed back up into the spindle, your Haas should perform well.
Use coolant
how much power do i need to machine steel?
One of the great advantages of high feed milling is that less power is required compared to using a milling cutter with a square shoulder. Still there are a lot of variables. Cutter diameter, material, insert, cutting conditions all play into it. In the video we are using a Mazak VCN-510C with 25 HP spindle. You can be successful with 20 or even 15HP, but you may have to stick with smaller cutters. We like Walter Cutting Tools, but most major tooling manufacturers will have high feed cutters. You should request that one of their techs come in with a test cutter to help get you started. They should do this for free.
Such an question xD
less than aluminum generally. its more a torque problem because the rpms are generally low and way down on the power curve of the spindle. smaller cuters can utilize more horse power beacuse they can cut at higher rpms. for example 0.5 endmill with a 12% stepover runs 6600 rpm at 140 ipm. a 2 inch high feed mill will let you reach way down but your rpm is more like 1200 to 1400. Modern coatings cant handle the heat of cutting steel like aluminum. The most important things for cutting steel are setup rigidity and cutter rigidity. remember cutter stiffness is a cubic function so for every one times D you add you lose 3 times the stiffness for a given diameter.
why no coolant?
horseshoe182, in most face milling and high feed milling roughing operations coolant is not used and actually decreases insert life. The coating on the inserts requires high heat to transform to a harder ceramic. To get the high heat no coolant is used. When the speeds and feeds are correct, all the heat goes in the chip and the part is cool to the touch.
Thermal shock caused by the Coolant cooling the Insert as it leaves the cut only for it to immediately be heated up again as it re-enters the cut over and over and over will cause premature insert failure on Interupted cuts often seen in Milling Applications. Turning not so much. And I agree that All Manufacturers Insert Grades are so advanced that many work fine without coolant. Just have a ton of high pressure air to clear chips to reduce recutting them and you can do well in many materials.
ups.
just a dru run ya.
Tanto vale usare una fresa con placchette rotonde, qui addirittura c'è già il pre-foro
Guiseppe, Una fresa con un inserto rotondo funziona anche in questa applicazione, ma è necessario per ridurre la velocità di avanzamento. Utilizzando gli inserti di avanzamento elevate massimizza il processo.
Faster then a Bridgeport , ,take a good peck .100 more
It would be better in a horiz ;)
Not without out air, trust me I welded chips to the holder cuttin on a boring mill be cause the air shut off
Agreed that a horizontal always helps with chip evacuation, but you have to work with what you've got.
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That is everything but not High Speed Cutting... or High Feed Milling...
Hifead? nice joke.
Jszyndlar "Hifead?" Nice spelling.
why don't just drill bigger u drill and bore the hole if its accurate,for me it looks stupid what you doing.finish looks worst and time you spending if use u drill you can easily finish two.
Only to you does it look dumb. How many boring passes would it take? How big of drill can you productively run? It's ALL about metal removal rate; however you get that number depends on a lot of variables.
If this is a sub con job the price of a u drill would probably be more than the job. Helical bore milling is a great machining strategy for all types of holes that you can use your existing tooling to generate the varied requirements of multiple jobs.