Experimenting with a High Feed Mill! WW207
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- Опубликовано: 25 авг 2024
- High feed mills! What are they, what makes them unique, and where do they shine? It all started with the Tormach DIJET Modular Insert High Feed mill on the 440. If you haven't already, you may want to consider adding high feed mills to your toolbox. Let's test a solid carbide .240 diameter high feed mill from Lakeshore Carbide on 4140 steel! Will it be a viable and reliable option for slotting?
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Links for this video
Tormach DIJET High Feed Mill | bit.ly/2lFVAzD
Lakeshore Carbide High Feed Mill | bit.ly/2Ky3vwM
CNC Machine P20 + DIJET High Feed Mill | bit.ly/2GKdYDL
Plunge Milling | bit.ly/2tD9pn0
Speeds & Feeds Excel Sheet | bit.ly/2zJtkpD
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Reach us / CNC Info:
Speeds & Feeds: provencut.com
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The issue with the small (under 1" diameter) inserted high feed endmills is that because they move so fast, the slightest chip on the insert gets worse and worse very quickly to the point that the insert blows and you have little time to stop it. Usually the tool gets destroyed and there goes a few hundred bucks. A 1/2 or 5/8 inch variable helix endmill with trochoidal cutting methods can rough out a slot or pocket very quickly and cheaply and once dull, send out for resharpening and do it again.
The smaller solid high feed mills are good for small slots and pockets and that's about it. Maybe some instances where a certain workholding method is more likely to cause vibrations and the solid tool would help cut down on those vibes and prolong tool life and reduce chatter.
Dick Tickles I run the integrated holders and exchangeable heads. Reasonably priced when you do kill them
Great video John. Thanks.
We do a lot of High Feed Milling, but usually with face mills 1" dia - 4" dia, and usually only for roughing. We use Ingersoll Tools Gold Quad and Midi conservatively at .030" and .020" per tooth and the same .030" and .020" DOC. We are usually cutting FX-2 Die Steel at about 400 SFM. Our typical feeds are 100-120 IPM.
Thanks John, very informative...Time is money of course but that is a pretty hefty entry price for the cutter...I can envisage tears in the coolant tray when it breaks!
Some great advice, thanks! I like to see how different styles of tools can be used
In a job shop often you don't get the huge cubes of material you see in tool demos. You make more parts that are longer and wider than they are tall. So you can't always use the full flute of a tool anyway. Using a 1 inch, 2 inch or 3 inch feed mill becomes hard to beat in terms of material removal rate. Even taking a small width of cut, roughing the outside of the part is extremely effective, shorter flute = less chatter. Plus using small inserts with 3+ sides means you save a lot of money on carbide. I don't know how math works out for the solid carbide ones. At my last job we did a lot of stainless and these things cut part time down immensely.
Love these tools especially the lakeshore carbide tool in this video! They really kick up the wow factor in a larger faster machine and start dancing around at 320 IPM.
A guy from Seco explained high feed milling to me in a way that made sense. His take was, essentially, that high feed end mills coupled with a high feed, low DOC strategy produces high axial force and low radial force on the end mill, tool holder, spindle, column, etc. This takes advantage of the highest plane of stiffness in the C shape of a mill, leading to a more stable cut and better all round results.
In a pinch I've run a high feed strategy with a standard 4-flute Guhring carbide end mill in 316 stainless on a Tormach 1100 with decent results.
Really like the spreadsheet. I could do with something like that for the guys at our place!👍
I used to work at a mold shop and we’d rough out entire cavities/cores with a high feed indexable cutter. Granted we used Makinos with high rpm spindles....
Kyocera MFH Raptor Mini (specifically .75 and 1.0) is pretty solid in my experience and 4 edges per insert.
i really like the high feed mills for tough steels like your cpm's and m series
I recently ran an 5/16 feedmill 7200rpm, 450ipm. In nitronic 50, it looked like it was broaching.
Strategy to go for internal contours with a lot of shallow angled areas. Instead of a purpose-highfeed endmill you can improvise with a bullnose endmill. If even works with a standard carbide endmill that has a corner-chamfer.
High feed is built for hard material or chatter prone conditions. Much prefer high feed to standard square indexables
nice , i saw some Kennametal high feed mills on their youtube channel . They pushed it at something around 12000mm/min feed . in STEEL . The mind boogles .
Not sure why but I'm not being notified of your vids anymore.
This is where the high Rpms come into play on these new machines, like I said before, it would have been cool to go even faster then the 7000 or so rpms on the 770.
I guess that is what the vf2SS is for
Cool stuff! Would've liked to see what kind programming strategies you used for the pocketing.
You have the koroloy pro x they do a high feed called hfm and hrm the hfm do small diameter ones which are really good you should have a look at them
I get the high feed mills if you don’t have the horsepower. I have used them I just love taking big cuts and smacking chips up against the door. I just started using an Iscar finishred and man it cuts I’m taking a .187 width of cut with a 1 inch depth of cut at 150 ipm on my fadal. The thing is a beast, and it lasts FOREVER
Jason Bone high feed mills aren't for the case where you don't have enough horsepower since there are also high feed mills which are 100mm in diameter. And those require some serieus power from your machine.
Tim Dijkhuizen you are right but in most cases they are really shallow depth of cuts
Jason Bone that's true, but they still require some good power and a Ridgid machine
Good video. Looks like you’re doing a lot of slotting lately.
Hey John,
great that you start using those small high feed tools.
When you do machine deep slots and pockets, try to use some tools with inner coolant holes and air through the spindle. It works much better then external air!
Greetings from Germany :)
Nico
Hey nice video and really educative. I have suggestion regarding to use milimeter also at your video. Because asia and europe region we use milimeter. It would increase your audience no only for us audience. Hope it help
I was excited about this tool, I do a lot of slotting.. But looking at the feeds and speeds chart on the lakeshore website, i do not see aluminum on there... Not good for aluminum I guess?
RacnJsn95 No real reason to use one on aluminum.
How do you accurately model these cutters in Fusion 360 to be able to do 3D machining?
With enough feed speed you can use your mill as a shaper ;)
I have always wondered how much more wear a high feed milling strategy puts on your machine.
Since you can effect avoid Chatter and the load on the guideways are consistently lower i would say that it is not so bad.If there is a better tool i will not use HFM.BUT in the last few years, i had to mill a few parts, where i was really happy to have access to this tools.
bcbloc02 It can be quite a bit less, if you think about it.
Could anyone tell me the difference b/w a 5 axis machine and Mill turn ...?
In terms of axis and where these machines can be used ?
Thank you.
Look at iscars multi master feed mill. I use one 16mm 4 flute and dog the crap out of it cutting h13 tool steel. Then finish it out with 5 flute 5/8 acupro endmill makes 2 slots 3 inches long 5/8 deep in like 4. Minutes
Just wondering whether a slotting saw would give you the slots in the piece you demoed more quickly and cheaply? For the rectangular pocket/any slot that's not straight through the part it's not an option of course, but depending on how often you need through slots vs. internal slots/pockets, I suspect the slotting saw option could give you more bang for your buck.
Tormach have a few other uses for them too: www.tormach.com/blog/3-things-using-slitting-saw/
I highly doubt it, especially in a light machine.
I have a 6 inch sandvik 210 facemill we high feed mill 120 imp and .079 depth of cut.
Dave Mcmasters .079 oh man those must be some meaty chips.
The 210's are a rough feed mill. I moved away from them and back to the Iscar wmot insert and the newer Ingersoll triangular insert feedmills in the larger diameter.
Big 6s and 9s Mauricio Espinosa
Are these high feed mills generally for steels?
Thepriest39 all sorts of materials
Thepriest39 Steel, iron, stainless, high nickel alloys, hardened materials, and more. Not a big reason to use them on non-ferrous materials, in my opinion.
Just watched the James Brutons from xrobots youtube channel (who also looked into the Johnny 5 build. nudge nudge) first go at CNC machining. actually gave you a shout out in his video. anyway It must be a relic of going to cnc from 3d printing but the tool paths most people start with are slotting with small depths of cut. this tool seems like a good place to start for beginners?
You forgot the metric guys this time. Sincerely yours a guy from Europe.
2:54 what? the feed per tooth is 0.03
ManMadeDesaster Yep. I’ve ran indexable high feed tools past .050” per tooth very reliably.
Because its basically a ball mill the SFM is not what it seems.
First!
First
Kedrick Johnson And?