We Pushed this End Mill Until it Broke… Then Backed Off
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- Опубліковано 13 гру 2023
- When CNC Machining, it’s important to maximize your MRR. We pushed the KOR-5 End Mill from Kennametal to the MAX, Until It Broke… Then we Backed Off to Find the Sweet Spot.
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Barry's "hmm" after the drill slams into the material always makes me lol. In all seriousness, these machines, tooling, and workholding are all TOP NOTCH.
Hi Trevor what were the speeds and feeds of the "sweet spot"
"Crash one gigantic drill into a part and the next thing ya know they dont trust you to make straight lines." Got me so cracked up laughing over here! It takes a real man to be able to crack jokes at himself!
LOL glad I could help!
I got a pretty high MRR using a countersink earlier today. Unfortunately, the material I removed was from the countersink itself 😅
Amazing and absolutly incredible!
Jessie, Barry and all of the team have great knowledge,...
Titan, however is not only conveying knowledge, he literally is the wisdom-keeper.
Sharing it with the world, a true hero -
I can just imagine the reaction of your machine repairman: "How in the world did you wear out all the bearings so quickly?"
NAH
True
.......uhhhh
...we have it on video 😁
As long as they stay below critical speeds and are clean lubricated, nope
@@seancollins9745 Bearing wear is determined by a combination of factors beyond lubrication quality. Temperature, pressure, and RPMs being three of them. High MRRs mean high pressure on the bearings. Why do you think engines built for racing need rebuilding more often than the engine in your Corolla? Because the higher power output levels cause accelerated bearing wear. ANY mill or lathe will experience faster bearing wear if run hard frequently. IT's time x pressure.
Another variable to take into consideration for MRR is the machine / controller processing ability, some older machines can't cope with high feed rates during complex toolpaths (trochoidal etc.) so you will need to increase the radial cut and decrease the feed rate to compensate.
Some older machines… or any haas without the hsm upgrade :)
Titan, awesome job explaining what you were doing and how you were getting there. Loved the egg being thrown by Jessie and Barry with Titan in the middle giving them the ammo LOL. Awesome job guys, that includes the video team too.
Oh man! Such a jam packed video of knowledge, as well as Barry! Aside from his quick wit and snappy one liners, his "ohh yess!" Sound effects are the best!
Glad to see you grow in the Machining Game Titan! I was part of the Lawson Drayage Rigging Crew that helped out with your Rocklin/Texas move. Great Job 😁👍
Great video as always, on what you said Jessie about 5 flute vs 2 or a 4, sometimes it’s really material specific , aluminum isn’t picky, our programmers forced me to use a 5 flute 3/4 in copper, ( this was a KOR 5 knockoff aka a helical brand endmill almost identical to the KOR5 in the video) when I said Iv experimented many times to go faster, and copper refuses to run good with more than a 4f, 3 being perfect, I tried every feed, speed, step over, axial engagement possible nothing worked. This was in a rigid setup as well , all endmills definetly have their place, I think 4f is the most versatile you can get, being a guy that specialized in copper machining for a couple years I’d love to see more videos using copper to get your expertise and perspectives.
Love the collaborative effort to see how far you can push these tools! 👏
I wouldn’t have believed that you could cut this much material in one pass! This is absolutely amazing. I chose the wrong career path; that flute design looks exactly how I pictured it, having never seen one before.
You guys are the whole reasons I have a hobby shop
Pedal to metal, show where the tool/machine limit is, MRR 650, 750, 1000? In other words keep pushing until it breaks or stalls. Push coolant to limits and measure tool wear changes. It fun to see how far it's possible to go which almost none do largely because of the capital costs of the equipment and tooling and this can make labor costs much less significant for part purchase, example a part with a low per piece labour cost due to machine speed makes where part is made more important as price differences narrow and shipping and supply line length become the dominate factor in purchase decisions.
This is a great video! So much knowledge to be shared in this
🎶 Volume up! Love the chemistry between these guys and the editors LOL. Heller machines are top notch
Love seeing the boys have fun on these tests. And those HELLERs are absolute beasts. Insane.
Really great info on how you cam maximize your MMR depending on your machine's capability. Grab them tools!
Always fun to figure out the maximum. Ive one part thats really thin, long and small width. I made a fixure grabbing it over the whole length on both sides. If I use the maximum feed for this material and tool the part breaks, chunks are getting pulled out of the fixture. I backed up the feed and its okay.
I dont have a vacuum chuck yet, have never worked with one, I will try that next to see if it can go faster. The width is only 40mm and I dont know how strong such a small vacuum chamber is.
you can calculate it,as the Vaccum pulls over a surface. Which is your part.Get the Square mm of the parts ( the face on the vacuum pad) and multiply it the holding force at your caccum. THere is a maximum of -1 atmoshpere(thats a real vacuum then). you cant do anything to get that holding force up from that max value.
Great video! I always enjoy seeing the Heller in action!
Now do that on the SVM4100 🤣 i while back i only got to around 60cuin/min in steel, gradually increasing feed while looking at the tool, when i was at 100% and the tool sounded healthy, i turned to the control and saw the spindle sitting at 180% load... tool was happy, spindle held rpm at 6k like nobodys business, pretty good for such a small machine
Finally you have come back down to reality and given one of the best examples of Metal Material Removal. Now tool life and tool life management are the next aspects of creating a reliable Manufacturing process. Remember at the end of the day we have to bring People-Process-Techonolgy together. Though I never recommend every trying to break and endmill. Not good for the holder, spindle and liner bearings.
"Crash one big drill"😂😂😂😂
Heller machines are simply monsters
So how do you acutually approach to calculate a sweet spot without using/ignoring the recommended speeds and feeds of the tool manufacturer?
What are the important things?
How do I know what my tool „really“ can handle, without having it wearing off like crazy?
6:00 , I love this joke, something meaningful to my job 😂
When it comes to the internet, information about machining is scarce and I’m curious. What does the final calculation for MRR actually mean? like, if MRR = 100, then what is it 100 of? Also I wouldn’t complain about a detailed explanation of MRR if someone feels so inclined.
They said multiple times that it's cubic inches per minute. Cut cross section x feed rate gives cubic length per time in whatever units you use. Obviously the 300 only applies to inches and minute.
What a great time to be alive!
How long does the mill last at 300mrr?
Thats awesome. Good to know.
Oldman always says theres more than one way to properly abuse a tool.
My lathe can go 1500jipm, but, it's a old boxway machine,chrome scraped hydrostatic Cincinnati milacron 300 ipm with 30hp spindle, it's easy to overwhelm the spindle. My hurco slv40 spiriti, I've replaced the ball screws and servosa shes 2000ipm capable now.10k rpm 15hp spindle, mrr is much better since listening to Tyson,
A video with a high speed camera showing the mill cutting into the material would be really nice...
What about stopping mid cut-for a more graphic visual on the depth of cut,etc. -I’d like to see that added to your presentations-love you guys-fighting the good fight-always entertaining-thank you…
FYI that 300in3 = 4,916cc
They will wear out sooner. But Titan's calculus is that the increased profits from the faster machining speeds will outweigh the added maintenance and repair/replacement costs.
Math meets reality!
I can smell the coolant lol
anyone MRRing at these rates in a typical shop would have all the other workers complaining!
Boom!
Bigger stepover means more heat and higher temperature shocks because of less coolant on the cutting edge during each cut.
In steel and also stainless I got the best tool life without fluid with high feed and small stepover, just air to prevent recutting of chips.
I really would like it when you do it a bit more scientific, not like the tool guys.
Play around and show a tool life curve with different approaches, but also with material removed.
That's something I'm really missing in this industry, the best approach for roughing and finishing in comparison to the tool costs.
Just trying until the endmill breaks is nice to see, but it would be really cool to know the tool costs per hour in relation to the mrr, that's something to calculate with.
Also I'm just a German potato, but I really like your open approach to push your industry, in Germany every knowledge is told behind closed doors and nobody knows or sees what stays behind the word "machinist".
That's also one reason why nobody wants to work with dirty and oily hands here...
And meeeeee again...😂
Really, that's my opinion, if there are trials with different roughing tools, different Carbide substrates, different rake angles, surface treatment etc.and price per cutting time combined with some kind of ai, combined with a cam software developer, maaaan, that's a plan for making good offers for customers 😉.
@Grobschmied87 Pretty much all you've asked for is at the regular Sandvik Coromant site.
Material, Application, Feed, Speed, Stepover, Downstep and amount of parts per insert corner
@@yanivchen6401 yes thanks for the information!
But this is sandvik only.
In my mind it would be great to have this information while generating the toolpath.
Imagine how cool it would be to play with some slides in your CAM and see your runtime and the costs, maybe also the break even point of your needed profit per part.
And the best is, the program is ready to use without filling in your cutting data in a online mask and put the results back in the Cam.
That will never be perfect but it's a great help for calculation.
So is this tool better than the Harvi 3 you've been pushing?? The Zombie mill??????
This tool is our favorite for aluminum. The Harvi3 and Harvi4 are for titanium and inconel, harder stuff.
"BOOM 💥" ..."and he even shut the machine down"
...........Barry, are you listening 😁
I love the way you guys think and work together. 👍
What about a desktop cnc machine where the rpms are high but the power is lower? Keeping in mind the largest tool i can fit is 1/4 in.
That's when you max out your feedrate with a lighter stepover
Thats when you throw the machine in the dumpster and get a bridgeport
@@Dillybar777 Cant do that. It’s my professor’s machine, but I’ll give him the recommendation.
I wonder if Santa is going to be bringing a new beast machine to Titan's for Christmas........??
Can anyone tell me what the only thing that matters is? lol 🤣
Rapidding giant drills into your parts? Lol
@@ThatOneFiesta lol yes!
With a 2 million dollar machine you should be able to do anything.
Is there an engineering called machine tool engineering?
And how is that MRR, respect that reccomended by the brand?
Respect the 100% reccomended
What is MRR?
Material removal rate; the total volume of material removed per unit of time
whooo whaaaaa так блять классно стереть кусок металла в стружку!! Так познавательно что я посрать забыл !
Aluminium games😂😂😂
These guys are having too much fun to call it work.
At 10:15 the MRR is actually 100 not 175,
2 inches deep, 100 IPM .5 radial is 100
I did the math also and i was wondering how did titan canculate
175mmr
@@stjepansvrtan9766 yep, it’s depth of cut X IPM X radial cut
Booom! How is this Video so great? :)
why you guys talk in MRR?..... talk about programmable values like stepover and depth of cut.
Always love the shit talking. lol
MuRRdering metal!
Where the bosses are looking
Titan there’s this general rule of thumb is that you don’t fuck with people when they’re working on a machine. I was not impressed to see you scare him like that
Is there an engineering called machine tool engineering?
Is there an engineering called machine tool engineering?
Is there an engineering called machine tool engineering?
Is there an engineering called machine tool engineering?
Is there an engineering called machine tool engineering?
Is there an engineering called machine tool engineering?