Another thing that is worth mentioning, end mills and collets with internal coolant supply also make a huge difference in deep pocketing. External coolant supply will often stop chips from flying away and push it into the pocket and tool, while internal coolant pushes it out of the pocket.
This is incredibly valuable. There are so many questions for someone getting into modern machining and a lot of it is as hard to pry loose as lore. Containing it all in the Haas ecosystem is a distinguishing feature between Haas and any other machinery company.
An option not mentioned in the video is a high feed mill. By running with low radial engagement, high axial engagement and high feed per tooth, we can get very good productivity in pocketing operations with excellent chip clearance. High feed mills also direct more of the cutting forces vertically into the spindle nose, which can be very beneficial in deep pockets that require a lot of tool stickout. Productivity with this approach tends to be limited by machine dynamics but spindle torque requirements are relatively modest, so it's particularly well suited to agile machines like drill-tap centers.
I switched from using standard end mills to roughing ones a long time ago on all our aluminum parts. They not only have a larger step over but also a higher feed per tooth and a higher surface speed, resulting in a much higher material removal rate. The (aluminum) roughers that I use have small teeth, resulting in a fairly smooth finish with almost no visible lines after tumbling. The only "problem" I have are the small chips these produce. A lot of those small chips do end up in the filter tray of the coolant tank. That is why I love some of my larger insert mills that leave me with nice large chips
Haas do offer a supplementary chip tray filter kit, which will filter out smaller chips than the standard chip basket. That aside, I'd much rather have a chip end up in my coolant tank than be rattling around in a pocket.
@@j.dietrich I know and we do have this installed on our machine and it actually works great. I was surprised how little chips I found last time I cleaned the coolant tank. I could easily mop them up with shop shop towels and the in-line filter basket that sits on the back of the machine stays empty. The tray does fill up fairly fast though and I need to clean this out on a daily basis - twice on a good day. I made a habit of mopping all chips on a dust pan with a rubber brush (the type that is being sold to sweep up hair) in the afternoon and let it drip out during the night.
Thank you for this Mark. Question: I run a lot of one offs, and sometimes they are burned to rough shape on the plasma. Recommendation for cutting the rough plasma edges? Thanks again.
The thing I don't like about roughing end mills IS the little chips, they get everywhere and you have to be soooo careful to clean your vice jaws on 2nd op work, so you don't get chip dents in the finished surface of your part.
I work in a. Copper only department for semiconductor parts. We can’t have a single scratch or dent on parts, and copper is softer than butter. It’s so annoying😂 even if a spec of a hair is clamped on it will dent your part I’m not exaggerating, and if the part slides at all while clamping the vice it will scratch even on the smoothest fixtures.
yes, roughers leave behind metal mud that goes everywhere. Shits fucking awful, gets in your pockets, your shoes, hair, inside way covers, in the coolant tanks, shits fucking trash. Cycle time savings arent worth it when you gotta spend 15 minutes cleaning the entire shop of the metal sand they make between parts.
@@romanfedotov9434 that’s why I’m our big shop we pay guys to clean our machine and it’s filters out😂 when you got 100+ machines it saves a lot of money to pay someone less to do that
@@skaelring-xj3gq what do you do ? Not a lot of shops that machine copper, also, it drills like shit and don’t even get me started on turning it in a lathe😂 it is by far the worst material in a lathe I have ever machined
More gold from you guys. Thank you for doing these type of videos. Don't do a lot of pocketing and never considered what a rougher could do to fix this particular problem. As others have posted: the finely grated chips might be a problem in the coolant and auger. The chip splitter seems like a great compromise. Thanks to this video, we're all equipped to make that decision now. Thank you again.
It all depends on how stable your setup, workholding and toolholding are. Yes, you can usually cut with the full length of any end mill, but you will need to lower your radial engagement, or your feedrate. When we slot with an end mill, at full diameter, we will need to go slower than when just profiling, engaging just 10% of the endmill diameter in the cut.
If you didn't have a big thru hole in the middle of the pocket, that rougher endmill would have recut chips way worse than the standard one. The small steel chips created by the rougher are too small and heavy to be blown away by the coolant and end up piling up in the pocket. The solution is to use toolholders that don't obstruct the coolant flow into the pocket and the chip movement out of the pocket.
CrypzXonics, This link will take you to the HaasTooling End Mill page with the filter selection set to our HEPM "chip splitter" end mills. www.haascnc.com/haas-tooling/milling/end_mills.html?scroll=true&Haas%20Milling%20Series=HEPM This 2nd link will take you to a 1/2" HEPM Chip Splitter end mill just as an example: www.haascnc.com/haas-tooling/milling/end_mills/03-2144.html
The video has a very funny but unfortunate typo. The machinist is stating he was having trouble with his end mill, but the TYPO wording swapped end mill with enema. Whoever made this should correct the typo so as not to embarrass the man, who gave up great information. You'll see it at the 6:36 time mark.
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I'm a 2nd generation machinist,I realised that I just watched hours of these tips, with a small alliminium part in my hand, being proud of my work
very useful video, I have not yet seen a more visual comparison of finishing end mills with roughing
Another thing that is worth mentioning, end mills and collets with internal coolant supply also make a huge difference in deep pocketing. External coolant supply will often stop chips from flying away and push it into the pocket and tool, while internal coolant pushes it out of the pocket.
From my manual hobby machine 2:40 is a sick cut! :D Very educational, good job
Another informative video highlighting Haas and Mastercam driving the toolpath. But what is even more valuable is the knowledge shared by Mr. Mark.
Mark, thank you and your team for these wonderful videos. TOD helps me a lot in learning. Thanks a lot!
This is incredibly valuable. There are so many questions for someone getting into modern machining and a lot of it is as hard to pry loose as lore. Containing it all in the Haas ecosystem is a distinguishing feature between Haas and any other machinery company.
An option not mentioned in the video is a high feed mill. By running with low radial engagement, high axial engagement and high feed per tooth, we can get very good productivity in pocketing operations with excellent chip clearance. High feed mills also direct more of the cutting forces vertically into the spindle nose, which can be very beneficial in deep pockets that require a lot of tool stickout. Productivity with this approach tends to be limited by machine dynamics but spindle torque requirements are relatively modest, so it's particularly well suited to agile machines like drill-tap centers.
Every high feed mill I’ve used has low axial engagement and high radial.
That makes a lot of sense, but it doesn't seem like a good fit for the parts demonstrated in this video.
@@poetac15 😂
*axial engagement
You definitely meant high radial and low axial 😉
Air blast, not coolant, and the chip breaker makes a big difference. You also get a lot more material in your chip bins for disposal.
I switched from using standard end mills to roughing ones a long time ago on all our aluminum parts. They not only have a larger step over but also a higher feed per tooth and a higher surface speed, resulting in a much higher material removal rate. The (aluminum) roughers that I use have small teeth, resulting in a fairly smooth finish with almost no visible lines after tumbling.
The only "problem" I have are the small chips these produce. A lot of those small chips do end up in the filter tray of the coolant tank. That is why I love some of my larger insert mills that leave me with nice large chips
Haas do offer a supplementary chip tray filter kit, which will filter out smaller chips than the standard chip basket. That aside, I'd much rather have a chip end up in my coolant tank than be rattling around in a pocket.
@@j.dietrich I know and we do have this installed on our machine and it actually works great. I was surprised how little chips I found last time I cleaned the coolant tank. I could easily mop them up with shop shop towels and the in-line filter basket that sits on the back of the machine stays empty. The tray does fill up fairly fast though and I need to clean this out on a daily basis - twice on a good day. I made a habit of mopping all chips on a dust pan with a rubber brush (the type that is being sold to sweep up hair) in the afternoon and let it drip out during the night.
My favorite youtuber :)
VERY educational. As usual. Thank you.
Great video, thank you! Can you do a similar chip control video for lathe turning? We have an ST-15Y in our shop.
Thank you for this Mark. Question: I run a lot of one offs, and sometimes they are burned to rough shape on the plasma. Recommendation for cutting the rough plasma edges? Thanks again.
The thing I don't like about roughing end mills IS the little chips, they get everywhere and you have to be soooo careful to clean your vice jaws on 2nd op work, so you don't get chip dents in the finished surface of your part.
I work in a. Copper only department for semiconductor parts. We can’t have a single scratch or dent on parts, and copper is softer than butter. It’s so annoying😂 even if a spec of a hair is clamped on it will dent your part I’m not exaggerating, and if the part slides at all while clamping the vice it will scratch even on the smoothest fixtures.
Well, if your pocket id deep and you are not breaking chip, you will scratch inside with chips. There is always tradeoff.
yes, roughers leave behind metal mud that goes everywhere. Shits fucking awful, gets in your pockets, your shoes, hair, inside way covers, in the coolant tanks, shits fucking trash. Cycle time savings arent worth it when you gotta spend 15 minutes cleaning the entire shop of the metal sand they make between parts.
@@romanfedotov9434 that’s why I’m our big shop we pay guys to clean our machine and it’s filters out😂 when you got 100+ machines it saves a lot of money to pay someone less to do that
@@skaelring-xj3gq what do you do ? Not a lot of shops that machine copper, also, it drills like shit and don’t even get me started on turning it in a lathe😂 it is by far the worst material in a lathe I have ever machined
More gold from you guys. Thank you for doing these type of videos. Don't do a lot of pocketing and never considered what a rougher could do to fix this particular problem. As others have posted: the finely grated chips might be a problem in the coolant and auger. The chip splitter seems like a great compromise. Thanks to this video, we're all equipped to make that decision now. Thank you again.
Great video and very helpful.
Thanks
Spindle torque is the answer, to figure correct feeds And speeds, harvy end mills kenametal !
Thanks for valuable information.
Good video 📷📸
MISSED YOU TERRYBERRY
Great tip. Thanks
Thanks sir
Amazing job! :)
Can i cut with the full cutting length of the endmill with hss endmill?
It all depends on how stable your setup, workholding and toolholding are. Yes, you can usually cut with the full length of any end mill, but you will need to lower your radial engagement, or your feedrate. When we slot with an end mill, at full diameter, we will need to go slower than when just profiling, engaging just 10% of the endmill diameter in the cut.
Ahhhh. Love good info.
VERY VERY NICE, THANK YOU
How about end mills with TSC holes in them?
They are very expensive but that is an option
Super
Babe wake up, new TOD just dropped
If you didn't have a big thru hole in the middle of the pocket, that rougher endmill would have recut chips way worse than the standard one. The small steel chips created by the rougher are too small and heavy to be blown away by the coolant and end up piling up in the pocket. The solution is to use toolholders that don't obstruct the coolant flow into the pocket and the chip movement out of the pocket.
Chip splitter endmills where dose one find these
CrypzXonics, This link will take you to the HaasTooling End Mill page with the filter selection set to our HEPM "chip splitter" end mills. www.haascnc.com/haas-tooling/milling/end_mills.html?scroll=true&Haas%20Milling%20Series=HEPM
This 2nd link will take you to a 1/2" HEPM Chip Splitter end mill just as an example: www.haascnc.com/haas-tooling/milling/end_mills/03-2144.html
this is a standard end mill
and this is a metric end mill
I lmao at the joke about chips have seen things
use 100 bar tsc tho
5:13 😂😂😂🤣🤣🤣🤣
Or run TSC mill
The video has a very funny but unfortunate typo. The machinist is stating he was having trouble with his end mill, but the TYPO wording swapped end mill with enema. Whoever made this should correct the typo so as not to embarrass the man, who gave up great information. You'll see it at the 6:36 time mark.
roughing endmill sounds great till your chip filter is clogged every 5 minutes
in my house, i have no control of the chips
I feel like this comment didn't get the credit it deserved.
@@MrMattiepan lol
Awsome🫡
russian languare subtitri?
Teach about additive manufacturing
HAAS does not do those procedures.
Pls edited it its boring
3D printing plastic & metal
Я смотрю у лысого была бурная молодость😂😂😂😂