Endmills, Face mills and inserts - Where are the limits?
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- Опубликовано: 4 авг 2022
- mind bending research into submicron world of milling tools and surface finish.
I have spent over 3 months investigating this and I'm proud to share the results :)
list of the tools in the video:
pcd ball endmill: s.click.aliexpress.com/e/_Dmx...
pcd endmill: s.click.aliexpress.com/e/_Dkj...
MCD real diamond insert: s.click.aliexpress.com/e/_Ddn...
MCD real diamond chamfer: s.click.aliexpress.com/e/_DEo...
winstar endmil: www.winstarcutting.com/product...
blue face mill - ISO20 ISO25 FMB22 CNC tool holder: s.click.aliexpress.com/e/_DcA... 
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This channel is crazy underrated. There's so much good info and production quality even in the early videos. Keep up the good work
To be fair, not everyone is a machinist. This is a niche topic and I bet half my ass even some people of the same profession/hobby as him would find this tedious as a subject for a video to watch. But hey, I watched it!
Wow! I thought I was crazy for spending months taking a thousand photos with 30+ different end mills on 3 different CNC mills all in the name of finish quality on 6061. There is a lot of bad information when it comes to surface finish. I love that you share behind the scenes of Swiss quality level work.
hahaha :) good to know there are other crazy people around :) I seriously thought its only me who cares so much for the surface finish. thanks for the comment!
@@PiotrFoxWysocki if you can dial it in on the machine, you can spare yourself any additional polishing by hand, lets face it, no one really likes to do that.
Absolutely awesome. The content is fascinating and the quality of your camerawork and production has improved massively. It's just a shame that I can only click the like button once.
Hey 👋 thank you, glad you like it. If you want to do more you could always click "thanks" button 😉
Beautiful work, this deserves more views, this is what youtube should be
Thanks 😊 and I agree 😉
This and dog videos
Aftet 12 years of being looking for a channel like the yours, I found you!!! Thank you so much for this REALLY IMPORTANT INFORMATION!
I LOVE THE CONTAIN!!! 🤩
Wow 12 years 😉 I'm happy you found me and you will find the content helpful. Thank you 😊
I miss your videos, I hope you can find some time for making more. I have learned so much here, your content a real blessing for the world ❤
A very interesting video Piotr. Nice to see a deep dive into surface finishes and cutting edges. I can see you take great pride in your work. It shows up in everything that you do. Thanks for taking us along for the ride.
Glad you enjoyed it ;)
Incredible video, the photograph is implacable.
Great work.
The sheer capabilities of this microscope! Would be a MAJOR addition to my dream “Open Source Materials Science/QC Lab”
To be able to not only see, but *3D Scan and Focus Stack* reliably and repeatably is AMAZING.
I’ll try and document parts and whatnot the best i can and try and get a BOM up, but I seriously cannot thank you enough this project has me awestruck!
Just WOW! Looking forward to next part, can't wait. You leave no stone unturned. Your content keeps getting better, please keep it coming! 🙏
I was hoping that by making this video I kinda closed the chapter of the endmills. Looks like the demand is strong for more 😉 I guess I will have to make a video picking the best endmill out there. But this would take quite a while and quite a lot of funds to get a decent number of endmills to check. Any sponsors out there??? 😀
wow. fascinating and glorious to behold and always an absolute pleasure. just never enough! mirror finish 3d milling sounds too good, i can not wait! thank you for making these exquisite videos for us Piotr! happy to see you doing well!
Thanks 😊 this mirror finish fixation has to stop 😉 one day 😉
Im absolutely stoked for the next video!
Nice work! Some really interesting data points on the different endmills/finishes. Thanks for taking the time to do this. Criminally underrated channel!
Glad it was helpful! i have to say that your channel is also Criminally underrated! you have really cool stuff in there
@@PiotrFoxWysocki Thanks man
Suit looks sick!
Great job. It is so nice to see actual data from different milling procedures. Thank you for the video.
Thank you for watching 😉
Really looking forward to your next video!
One of the few videos I've ever seen which resulted in an instant subscribe & notify. I'm looking forward to seeing where your explorations take you in the future.
Thank you, 😊
Really impressive work, well done
Pretty fantastic! Thanks for all your great videos.
Thanks 😊
Nice job. The production quality of your videos has increased a lot over the years.
thanks. i'm trying to go proportionally to the amount of subscribers. funny you noticed it just after i basically removed my self from the video :D wondering how replacing my voice would improve production quality :D
Instantly subscribed. Thank you for this in depth look!
👋 thanks 😉
Love you boss. Very informative you have done those things which I imagine to do.
You are doing things I have always wanted to do, but lacked resources. Thanks for doing this..., Great video.
Thank you 😊 resources are always problematic
Use Blu Tack when imaging to remove all impurities, this is what we used in a study I was a part of. Im impressed by your homebrew microscope!
Also im sure you're aware of this but different endmills have different "edge preps". Steel tools have honed edges so they dont chip. Aluminum tools are super sharp and highly polished to avoid buildup. Maybe that Xuhan endmill was for steel?
Im wondering if the dark valleys we're seeing in the images is "waviness" (it seems when you went a little slower the waviness went away)
I challange you to make a homemade profilometer :D
The blue tack idea sounds great! I will use it next time.
Actually Xuhan end mill was for aluminium, plastics, etc. not for steel.
waviness I believe was caused by inserts not being perfectly aligned.
The bigger the gap between cuts wider the imprint of the insert cutting edge. when I went super slow, all the cutting was done by the lowest point of one insert.
homemade profilometer :D ha ha ha :D tempting :) but i think it would be cheaper and better to just buy one than spending countless amounts of time and money reinventing one from scratch :)
I would really like to have one but I just cannot justify spending money on something which I will use just to satisfy my curiosity.
@@PiotrFoxWysocki Yeah, I hear that! Plus you would need one just to test/qualify your homemade one.
Incredible images, such a great job
Thanks 😊 glad you liked it 👍
Wow. First video I'm seeing from you - instant sub. Really exceptional work.
Thank you very much! i just hope i wont disappoint you later on ;)
Love your zooming microscope camera! The footage is top class! Great vid . . . thanks Piotr!
Thank you 😊
Just found you.....you are going places my man....fantastic vids and quality. Keep it up
Thanks 😊
Hey Fox~
You are the jewel of the RUclips sea.
Thanks to you, my cnc is also improving day by day. thank you so much~~
Happy to hear that!
Amazingly awesome stuff!!! Thankyou for sharing!
Thanks 😊 and thank you for watching 😉
Amazing project!
Awesome work man. Super cool!
Thank you! :)
very good job! Thanks for all these informations, and cheers from italy!
Grazie mille 😀 greetings from New Zealand 🇳🇿
Fox.. Ready for another video.. Merry Christmas.
Sorry, I have been busy recently. I guess it's a time to make another one 😉 happy new year 🎉
fantastic video. thank you for spreading this knowledge and preaching the nuances of even cnc machining ;)
Glad you enjoyed it! :)
This is a fascinating video, I wish I had the tools to create these kinds of microscopic views on tooling like this. Just got the $50 eBay special which does an okay job of looking at things close up. Thank you for putting together such beautiful content.
Thanks 😊
This was incredibly cool
This channel is reminiscent of Breaking Taps, in a lovely way. A bit more slow-paced, but still just as informative. Gorgeous camera work!
Thank you 😊 much appreciated
Wauw. First video watched, instantly like and subscribe! Very valuable and so much effort put into the video! Thank you.
Thank you 😊
My mind is blown. The camera rig in just plain nuts.
Yeah. It's not bad. Does the job quite well. You should see my other rig for bigger stuff 😉 that one is nuts 😉
Amazing content 👏🏻👏🏻👏🏻
I really wanna see the results of machining steel on this machine 👍🏻
Thank you very much for this video. Very interesting. Thanks for work. Also you mill is awesome. Best regards
how's your harmonic drive, haven't seen any video updates?
@@JesseSchoch hi, currently I work on my small mill ... so no news regarding gears ...
Looking forward to seeing those diamond ones.
Same here 😉 can't wait to put my hands on them
This was very very interesting Piotr. Thank you. (I can only imagine how enamored with your work This Old Tony is)
Thank you 😊 but I don't think This Old Tony does know about my existence 😅
@@PiotrFoxWysocki I hope you get inspired to make more content soon. We miss you
My new fav channel
Takes my ebay microscope peeking at new brand endmills i bought to a new level. (its amazing how bad some new stuff is)
Awesome content
it's only bad if you have something to compare to ;) under such high magnifications, everything looks bad ;)
Nice work!
Thanks 😊
Hey u have revealed many things, gr8....
Brilliant. Really interesting and thanks for sharing
Thanks for watching 😉
Another amazing video! Thank you!
Thank you 😊
Learned a lot, great stuff !!!
Glad to hear 😉
good info and production quality
Thanks 😊
Alu-power series from YG-1 Is the shiniest endmill I know of, best finish I've ever seen from and on a carbide tool. The edge seems to 'burnish' pretty quickly but they have some kind of special edge prep they do to get the thing so damn shiny.
I will get this one to do more comparisons with other endmills. Any idea where to get dathron endmills?? US store doesn't ship anywhere outside US And Canada. I did contact dathron, but they are ignoring me 😉
So much reliable info!
Glad you liked it 😉
Extremely well done video.....the detail exposed in cutting tools is not apparent to most people who just get one out of the box and hope it cuts well.
I was one of them 😉 but it was bothering me why some endlills cut better than the other ones. I had to check and understand why, so I can move forward.
Przypadkiem tu trafiłem, chociaż nie zajmuję się CNC, ale widzę ładne ujęcia, quality materiał, rodak zrobił trzeba dać plusa :)
wielkie dzieki :D
I don’t have anywhere I can use this information but it’s fascinating
You never know 😉 in my opinion is better to know more. Than not enough 😀
Fascinating- thanks for sharing 🙏
Thanks for watching 😉
Great video. I learned a lot. I work for a small auto parts supplier that makes transmission and steering components. So many headaches could be avoided if operators would learn some of these concepts. I always carry a jeweler's loupe in my pocket because so many machining problems are rooted in tiny, microscopic, variations. It is shocking hard to get people to understand that a blunt tool, that is dragging chips with it, can gouge a surface and cause a cut to measure larger over time.
For example, one of our parts has a hole that is reamed at a 6mm diameter with a +- 15 micron tolerance. Over time, the reamers always fail because of large diameters. I will remove the tool and look at it under magnification, then tell the operator, "The tool is chipped. It will have to be changed." I have been told many times, by experienced machinist, that a chipped tool cannot cut a larger diameter. I eventually learned to explain it as a surface finish problem and most machinists "get it" then. We also run into this problem with broaching tools. The broached gear diameter always gets larger as the tool is used. Failed tools always show chipped edges.
hey, thank you! glad this was helpful :) +- 15 micron tolerance must be a real pain.. You shared very interesting story, I'm going nuts on the surface finish so i dont have to hand finish parts before anodizing. it saves hundreds of hours of unnecessary work. I didn't expect anyone else would go as far. glad to know i'm not the only one :D
@@PiotrFoxWysocki You are not the only one who tries to achieve these levels of precision. (: Precision air bearing spindles can require +/- 1um flatness across a 100mm face. Granted, the critical surfaces are also ground, but some of the non critical surfaces are only pcd turned.
Super cool video. For some reason it didn't come up in my sub box when first posted..
I have noticed youtube changed something in recomending videos and your feed if populated with most popular videos on the topic you watched recently. Kinda skipping the channels you are subscribed to. So you have to go and check your list manually. Kinda annoying..
I'd love to see a close look at surface grinder finishes. When is the DIY granite surface grinder coming?
Why do I need a surface grinder if I have cnc perfectly capable of doing mirror finish 😉
Magical, that is a good woodoo here, can't wait for diamond part))
Great, closeups segment could be a little bit longer as time (10-20%), or maybe each tool could deserve its own video(maybe, depends how hard it is, with thoughs and more talking discussing what is seen)
Great stuff, turns out that optics is still good for the stuff, nice
Those end mills shown in the video, were just to show how they are made. In my opinion brand is not very important as the technology of making those endmills is pretty much the same. This was related to surface finish only and overall better understanding of the tool. Now I know what to look for, buying new endmills.
BTW, the optics are totally different now, similar magnification but much better quality. chromatic aberration was driving me mad :)
just stellar!
It would be interesting to compare with and without cutting fluid, including isopropyl. Also would be interesting to look at flycutting, not sure if you would want to run one on that spindle. You could make a flycutter with a diamond insert, that would probably produce a great finish.
Isopropyl does help a bit. But it's not a huge difference. I think oil would make more sense as it would prevent aluminium from sticking back.
@@PiotrFoxWysocki zobacz nowy odcinek titans cnc. Mówią wlansie o chlodziwach oraz lubrykantach. To ma zajebiste znaczenie
Yeah, each or at least few mills diserve to be put trough different conditions fluids, oils and such to see how it affects things, it could be a next video or a spinoff of this one after diamond ones
@@PiotrFoxWysocki I heard about "trick" to spray denatured alcohol on aluminum for finishing to achieve mirror finish.
It does improve surface finish at some stepover, but if you go too slow it doesn't help. I guess for super shallow cuts/slow come form of oil would make more sense as tiny aluminum chips are very sticky. So something which could prevent them from smearing would work better 🤔 I would have to test it, or if someone experienced in micro machining could comment on it. That would be great 👍
I know in a previous video you used YG1 Alupower endmills and as I recall you were fairly impressed with these endmills. I also use these endmills and it would be very interesting to see how the grind and edge sharpness of these compare to the best of the presumably cheaper chinese endmils.
With the naked eye these endmills look superb in their grind, but looks could be deceiving.
Thank you for the very interesting content on your channel. Keep it up...
i think someone was recommending those but i don't remember buying them or talking about them. are you sure you haven't confuse me with someone else ? :D
Sorry then... maybe I have confused someone else's video with yours. None the less, I would love to see a comparison of top quality endmills vs chinese endmills in relation to the quality of the grind and sharpness under high magnification.
Keep up the good work! 👍
Can confirm those 3 flute alupowers make a niiiice finish. Really impressed me.
Thank you, for going so deep. havent seen the video yet ;)
Great video!
mono crystalline?! finally some REAL diamond cutting. sick
Yup ;) I'm curious my self 😉
Very cool review like I have never seen and informed.
Thanks 😊 glad you liked it 👍
Extra interesting, easy to listen to. Subbed here.
Awesome, thank you!
Solid!
Top KEK!
Mad stuff!
Fascinating !
Yeah! It got me quite bad, felt like Alice falling in to the rabbit hole 😉
Cool workshop
Thx
thanks for sharing!
Thanks for watching 😉
Stunning!
Thank you! 😊
@@PiotrFoxWysocki new favorite channel, binging your back catalog
I do the same thing when I find a new channel 😉
Hey Piotr what sort of Vc are you using for this blue face mill on aluminium ? Also the link for that mill is not working anymore
Thanks a lot. Top content
Glad you liked it!
I like your detailed scientific approach, this is what makes me appreciate the value of good tools and machinery. What is the brand of your stereo microscope?
thank you, link to my stereo microscope s.click.aliexpress.com/e/_DmQ12sT ,the footage in this video is from the microscope i have build my self, not the stereo microscope. just to make it clear :)
Super interesting.
Glad to hear that 😉 thanks 😊
I would be curious to see what you think of Datron endmills. They show off very special finish quality from their machines using their endmills. They have special single flute endmills for aluminum and use isopropyl for cooling or as a cutting fluid.
I dont think there is a big difference, because it is still a endmill. Good part is that's a single flute so runout is not so important. Datron had its own diamond fly head for only 2.5k usd 😉 when I checked. And the difference between them using their own endmills and fly head was huge.
@@PiotrFoxWysocki I understand. Thanks for the excellent explanation.
@@PiotrFoxWysocki the 4 in 1 endmills do have a wiper flat on the bottom, ive used them on a high rpm spindle (40k) and they seem to get better finishes than a xuhan endmill (but i guess they aren't the greatest) ive also noticed its realy difficult to clog them, I did pretty much all machining dry and never had one clog even with full slotting
Any brand in particular?
You are just awesome. just an idea, use your facemill with one insert, so you have no problem with height adjustment. (basically a flycutter). blue tag might help removing dust chips... from the surfaces before imaging. could you make a comparison between different surface finishes by different types of manufacturing (milling/turning, ground, lapped, honed, edm)? I think that would be really interesting. Also rough milled would be nice in comparison.
Hey 👋 thanks 😊 first thing when I got this face mill was to use just one insert. But unfortunately tool got really unbalanced. So I had to put other 3 to counter ballance it back. I guess I could use only 2 on opposite sides. I'm surprised you want to watch more microscopy footage ;) I thought one video was enough, so we know how things work and we can move on 😉
@@PiotrFoxWysocki I would also be really interested if the surfaces change after they were wrung together after all aluminium is soft. you are right the highspeed spindle needs a well belanced cutter perhaps add weights instead of inserts.
Surface was getting scratched more and more each time I wrung them. I think after 10x they didn't wanted to stick. That was the reason why I didn't thought it was even possible at first place.
Can you also do a fly-cutter which uses only a single cutting edge? Will it give better finish than the multi-insert facemills you've used here?
I will make one. Just as an experiment.
Nice job Fox. Can you do a run with cutting fluid-coolant vs crc or wd 40
crc or wd40 is not for cutting. isopropyl would be better if you really have to use some exotic stuff.
Hi Fox, great videos you have made. Can i ask what VFD drive you are using on your 2.5kw spindle, is it 240v 800hz , im interested in the 2.5 or 3.2kw atc 100/R24 Jianken but unsure of VFD. I'm another kiwi working from home cutting Ali, need to replace my cnc router spindle.
im using 2kw huanyang vfd, i have a video describing how to set it up. i should have matching vfd, but I'm trying not to run the spindle on 100% because I just don't want to destroy the spindle bearings. i was running other spindle at 100% and it lasted maybe 3 - 6 months, maybe 100h in total. so if you get a 3kw spindle get 3kv vfd. ask spindle manufacturer for recommended vfd for the spindle. give them, a chance :)
@@PiotrFoxWysocki Thanks for the info, Jianken emailed me back today, they have the 3.2kw 400hz spindle, 220v in 3 phase out through inverter, i don't run mine at 100% either, usually around 90%, been pushing it quite hard for a couple of years now, had to replace bearings twice so time to upgrade i think. Definitely like the results you have been getting with the Jianken spindle. I am looking for a vfd that i don't have to worry about, need one that is very reliable, as when the machine is working i don't have time for breakdowns, will keep the old spindle and VFD for a backup if needed. Cheers
Hey Fox, are you planning to do some close ups of the monocrystaline bit, then after use??
I wasn't but now I will 😉
@@PiotrFoxWysocki Great video and content as always mate👍👍
Another idea for a video might be a start to finish of how to generate the scan?
They look amazing!!!
It's really cool knowing the resolution of them.
Thanks again Fox!
Hahaha just remembered you've done that🤦🤦
Just rewatching it again 😂
There is plenty of videos on 3d scanning and photogrammetry. Beside when I made video about building the microscope, views sucked ball endmills 😉 so not many people want to watch it anyway.
I do not know how I get to these places. I don't do... any of this. Nothing in my life is remotely connected to this and yet... here I am... fascinated by a thing I have absolutely no connection to. Awesome.
That's exactly how I started this whole cnc hobby 😉
I'd love to see a comparison of these up against the YG Alu-power end mills...the grind of those are better than the 3 shown here in your video.
Yup. I will be testing those in the future once I have a big collection and I will make a endmills millout 😉 endmil donations are wellcome 😀
Where do you by winstar and your surface facemills?
Which ones do you recommend?
All the info in video description 😉
@@PiotrFoxWysocki thanks.
12:25 On the note of projects, i saw someone make a Single Point Diamond Turning Lathe who documented it quite well on RUclips if you are interested!
how about a link then?
@@jonjon3829 Sure! I'll post it in the comment below this in case RUclips freaks out:
(Edit in Case The Link Gets Hidden The Video is "I built an ultra-precision CNC lathe. (Diamond turning lathe project)" by "Cylo's Garage" )
@@ericlotze7724 /watch?v=PuSHpD7hiQ0 is enough
@@ericlotze7724 thx
Wow
Fascinating technology 😎😱
Glad you like it 😉
Yg1 alupower endmills leave a crazy good peripheral finish in aluminum and the price point is impossible to beat. Sgs and yg1 are my personal favorites. Sgs being the more expensive ones. Also Mitsubishi are king for indexables
Any particular model for best finishing endmill ??
I mainly use the sgs series 43 scarb, part #34713. This endmill is center cutting so you can ramp, plunge, and rough full radial and 1x dia. It is a beast. It also has wiper flats ground in it so it leaves a very nice bottom finish.
Have you ever tried using just one insert and leaving the other pockets empty? I've read it gets you close to a fly cut finish, may help reduce the inconsistencies you were seeing between different insert depths.
This was the first thing I did. Vibrations where quite big. So I would have to counterbalance it on the other side. This is getting quite tricky to do.
G'day Piotr 😀 Haven't seen a video from you for a while. I'm guessing you've obtained a contract manufacturing reverse engineered Alien technology, or perhaps the tolerances on your super cnc machine, while machining such materials opened up a doorway to another universe where you and the swarf got transported. Either way, hope things are going well for you, may the swarf be with you 😀
Good to hear from the Fox now and then. Hope you are well.
Ok you made me worried. Why do you ask? Do I look sick on the video ? 😉 I think I'm well 😉
@@PiotrFoxWysocki You haven't aged a day since the granite build. You look quite well Piotr. The audience is applauding in agreement.
6:23 It looks like a astrophotography picture 😁 Great video!
It does!
I do not do any milling but I enjoyed the video :)!
Glad you enjoyed it! :)
I've done a lot of single point diamond turning, I'm kind of surprised single crystal tools are being used outside of the ultra precision world. I did do some "roughing" of aluminum blanks using discarded diamond bits with a Hardinge lathe, got pretty nice results, around 50 nm rms with a lot of bearing print-through.
Yeah.. I'm suspecting that those tools might be too good for regular lathes. I'm thinking of making a lathe which won't have this print issues.
@@PiotrFoxWysocki Yes. Besides the rolling element noise of a typical spindle the are a lot of factors that would play against using monocrystal diamond tools. First and foremost, the cutting edges are pretty delicate. Since the edge is usually exceedingly sharp and the diamond is mono, this isn't surprising. Then there is the issue with carbide forming material that can rapidly erode the edge. And a lot of ordinary materials like extruded aluminum have inclusions that tend to beat the edges up. When possible, I used precision cast aluminum for optic substrates. If I used 6061 or such I tried to incorporate an electroless Ni layer to machine. Typical ball screw drives have lots of motion errors and this all prints through.
\
I was an optics guy, and all of my ramblings relate to machining optical surfaces, I don't know much about modern metal machining, so I'm surprised these tools are being considered for conventional machining.
i am interested in your ideas for an ultra-precision lathe. The typical modern diamond turning lathe usually has the elements of a massive granite frame, airbearing spindle, oil hydrostatic ways, linear drives (no ball screws), and feedback encoders with resolution less than 10 nm. Machine weight is in the tons. This is all to produce optically accurate and smooth surfaces. There are small intermediate tools for making contact lenses etc. I've thought about a small "Super toolroom" lathe that can make parts up to say 50mm diameter (100mm swing) with next level surface and form
BTW, I find having an air bearing spindle and some LVDT gages very useful for looking at roundness. My spindle is a vintage Precitech with inspection table but most any decent spindle can be used. If you can find one of the old Pneumo inspection spindle like was used in the Talyround, those are very nice
Wow. Lots of information here 😉 I don't think I want to go that far, definitely I want to build the lathe on granite. And use basically the same components I have used on my cnc. I still have 45mm linear roller guides.
I would like to have a good modern lathe which will have amazing surface finish, so i dont have to do any finishing and it would be a maintenance free machine. I just want to use the machine when I want and not to clean, Oil, tweak, adjust, fix every single time I want to use this thing. I guess my frustrations with my current lathe are coming through 😀
I just found your channel, so I want to see what you have done. I think machine components have gotten a lot better in the last decade or so, everything has on the optical side for sure.
My professional career is over, now I'm just fooling around with manual machines and telescopes. Well, mostly over, I've tooling my vertical mill to grind some laser rods. I'm interested in small CNC tools, might try to build one when I get a little more time.
Question:
How long does a bit/drill/insert last?
How perfect does a surface need to be til it's considered useless to go further beyond that kind of finish?
Will there be a change in surface finish if you use lubrication with the same exact setup compared to one without?
How long does a bit/drill/insert last? - it its really hard to answer it.
How perfect does a surface need to be til it's considered useless to go further beyond that kind of finish? - I'm pretty happy as it is right now because I don't have to do much of the finishing work before anodizing. But out of curiosity, I have to try what is behind the corner :)
Yes, lubrication is essential for a whole spectrum of reasons.
@@PiotrFoxWysocki alright, thanks.
Hi, first of all thanks for that amazing video. which winstar endmill did you use in the video? they are from Taiwan by the way ;)
Holly sh.... you are right.. they are made in Taiwan!!! What a ...
The endmill was a regular carbide endmill for aluminium 8mm 3 flutes. A100 I think 🤔
The "Chips" on the PCD tool aren't technically chips as you would normally think. PCD is a diamond matrix. i.e. Diamond particles in a binder. The different grades of PCD are based on the average particle size (in microns). When PCD wears, the diamond doesn't wear per se, the binder wears. When enough binder is worn at the cutting interface between the grains of diamond, the diamond particles are liberated from the edge and you are left with the gaps ("chips") you see in your photography. This is more akin to how a grinding wheel wears and will show up as an increase in Ra. Typically one should use a larger grain size diamond for roughing and a small grain size for finishing. This isn't the case for the mono-crystalline diamond.
thanks for the detailed explanation. i forget to mention about it in the video.
It is possible that diamond grains also wear out, despite the fact that the diamond is quite strong, but this strength is not infinite.
@@Redfvvg In my experience (>27 years designing, testing and using PCD tooling in aluminum high volume production), the binder is the weak link. Not that your statement is not true diamond can wear, I just have not seen that occur in my lifetime machining aluminum alloys - even in hypereutectic alloys.
Didn't even realize the grind pattern on the end mill will show itself on the surface finish on a part. Very interesting, how does one go about getting a 10rA or better? Dedicated finishing end mills with a fine grind pattern?
finer the grind on the endmill better the finish, but also you will have to combine it with flood coolant, and properties of coolant to prevent chips from sticking back. there is also PCD for mirror like finishes.
I run a prototyping and small production shop and have used quite a few mills over the years. We can regularly get 10ra with Garr Alumastar end mills, however to get that kind of finish does require flood cooling and a rigid machine.
@@nickanselmo6353 any experience with pvd or dlc coated tools? I've heard those can give mirror like finishes with the right setup
@@JohnBlaze505 we have some kennametal pcd inserts for a shell mill that do really well in aluminum. They claim to be good for steels too but the rake is way too agressive and I have never found a recipe that lasts more than a few minutes before chipping the inserts. They last forever in aluminum though with great finishes, we run a few continuos production parts and get ~2000 parts on one set of inserts. And thats just one edge, they have 4 indexible edges so they are great value when youre doing high volume