This Tool Keeps Breaking, Let's Figure it Out!
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- Опубликовано: 5 окт 2024
- After multiple breaks it's time to find the cause, and create a solution!
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You should really try to not use square endmills, a small rad will make a world of difference in the endmill's reliability.
true and aswell 4 flutes for this isnt so good for evacuation of chips . better 2 or 3 max.
I haven't used Fusion so I'm not sure if it compensates for it, but you will also have an increase in the apparent feedrate from the centerline of the tool to the outer tangent point of the hole where the cutting is actually happening. That can contribute to overloading the chip thickness. For a tool of diameter d cutting inside a hole diameter D, the feedrate should be adjusted (Adjusted Feed Rate, AFR) AFR = FR*((D - d) / D). So if you have a tool diameter of 10 and a hole diameter of 20, the adjusted feed rate would be 50% of the nominal value to hit the same chip thickness per tooth. The problem gets worse the closer the cutter diameter is to the hole diameter.
Thanks for this video John, and yes please, please keep doing short F360 CAD and CAM solution videos. I’m completely YT educated for my CNC mill in my home shop, and lessons from knowledgeable guys like you are invaluable to us guys. Thank you 🙏
I dont know your program structure so this might not work but on heidenhain we usually use CALL PGM to call the tool break check in a sub program. if you do it like that you could insert some Q magic if-statement stuff pretty easily to jump to an M65(or whatever your pallet change M-code is) if the tool is broken. That way you might not need to add it to every tool change line. But thats a maybe depending on how your program is structured.
Could you get rid of the endmill entirely and just drill the hole a bit deeper so the threadmill doesn't contact the bottom drill taper?
or just use a coolant through 3 form threadmill with endwork and eliminate all of the issues
@@carbidecuttingtools3783 less reliable
Good information on the flat bottom drill bit. Thanks for sharing!
They have threadmills that have a cutting edge on the end so they can plunge without a pilot hole. They are left hand tools and the spindle rotates in reverse while the plunge is right hand helical. You could probably eliminate the flat bottom drill by using one of those threadmills, so the process becomes: Spot/chamfer, pop hole, threadmill. I bet that would be pretty reliable for Ti.
I was thinking about these as well while watching this. I believe iscar and tungaloy make them as well as others probably. I first saw them on Adam the machinist page and he used them on stone hardened D2.
IDK about using that for the harder materials but they definitely have their place with aluminum and basic steel alloys.
Was missing these calls from you, John
Thank you
This is probably a super basic look at machining. However, It was illuminating for a muggle like myself. Thanks John.
Definitely. Ive been considering learning Fusion and it is useful to see how you use it and hear how you think about your models and programming.
More of this please. Would love to see a basic overview of macros. I understand the overall idea of them, but no idea where to start.
Peter smids book cnc custom macros is a great book to learn from
For those that want to watch it, one way to teach your team and show on RUclips as well, would be to have a split screen. Left side IRL cam with whomever you're teaching at that time, right side a screen capture that follows the mouse.
Excellent process video!! It's super scary to put your live program on display for everyone - talking about mistakes (or maybe not the best practice) is extremely hard so props to you for doing it!!
Dedicated Fusion tutorials, tips or tricks interspersed with your other content would definitely help you pick up subscribers from outside your immediate target demographic. Saunders picked up the majority of his long term audience through Fusion Fridays, and similar F360 content. They came for Fusion, and stayed for all the other business related content.
Neat fix and good idea on pallet change! 😊
You didn't mention coolant in your troubleshooting process. Has the coolant been checked for any degradation or contamination ? Also is the coolant flow directed in the proper place to flush out chips. If this process has been running good for a long period of time and then all of the sudden start breaking tools it may not be the process at all, it could be the tool itself or coolant issues. Sometimes tools from a new lot may be ground with clearances that are not suited for titanium .
Flat carbide drill exist for this ...
Didn't he talk about that?
+1 for basic marco how to. In fusion and in the machine control- where & how to access & implement macro code.
Good video. Have you thought about threadmilling on the way down instead of plunging into the material then threadmilling on the way up? Of course the real solution is to remove the issue with your flat bottom drill. But I was just wondering if you think that would have worked for you. Ciao, Marco.
More, please and thank you.
Thanks John for this nice Video! I would love to see more fusion tutorials 👌
No way I’m wearing a shirt that is almost identical to you in the video 😂 I love g code people think I’m a nerd at work for having shirts like that😂
I've got some treadmills that are spun ccw. They can also cut on the bottom. Don't know how well but maybe enough to clear out the drill tip.
We use to use a flat bottom carbide drill with tsc from the start where I work no problem ( we got about 2 weeks of tool life on each of them in high nickel material ( 55+ % ) where we then changed it with some tool life left. We rather change them before hand then having die in the part and scrap the part )
I think a helical ramp would easily fix your issues or maybe a flat bottom drill
Can you make one turn of the threadmill at the bottom of the hole and then go up in a spiral? So you get a semblance of a groove, and the screw goes a little deeper. Also tool wear will have less effect on the depth of a thread
since its a multi-point threadmill it would make a bunch of unwanted grooves, unless im misunderstanding you. on that same thinking most threadmills dont cut on the buttom face so you have to make room for it like john is doing.
Any reason for not spiraling in at a smaller diameter down to depth then profiling out the rest of the diameter - should be possible in the same pocketing operation. Definitely keep the pre drill operation. Don't panic about the time difference 10 seconds is quicker than replacing a bummed part and wrecked tool.
So ... does fault tolerance mean all the T lines are now based on global variables instead of static tool numbers, or does the Kern post have support for keeping track of sister tools internally? That's going to burn some serious brain-space keeping track of everything. Eager to see the results though. Good luck!
Thanks for sharing.
4 flute mills suck for that process. The relief at the center is getting clogged. The tip of the drill should go a bit deeper as well.
Why not just drill a bit deeper and run the tap or threadmill through it??? It looks like you have enough material to go deeper. Rather than a flat bottom drill you could use a drill with a weaker point (135 degrees rather than 118)? Lots of solutions. If you're getting 80 minutes of tool life from a 1/8" EM through titanium even that isn't terrible imo - I've seen milling setups where you have to change a tool every few parts.
It'll be cool if you can mix G-CODE and python with programs. In a language like python you could have an exception handler that does all the magic. You could have the tool change macro do the breakage detection and throw an exception that bubbles up the stack.
RS-274 G-code supports conditionals, loops and variables. It's not elegant compared to a proper exception handling system, but it's not horrible either.
@@j.dietrich yeah, I'm aware that some controls support a BASIC like syntax for G-CODE.
People absolutely do this, but they usually keep to themselves because there is a lot of specific applications which would make it pointless or at least very limited in use to justify sharing it.
Can you try a kennametal flat bottom carbide drill?
Kennametal quality has gone downhill lately, SPI or Ostrem are much better quality tools.
Why not use a sub program for checking for a broken tool? you would then just have to add a sub program call at the end of every tool.
Love these type of videos
wouldnt having the plunge centered also be better? since you would have more even distributed load while plunge cutting through the taper
Why don’t you use a thread mill that cuts the hole and threads with out a pre drilled hole. We use them with a lot of success. We use the moldino brand but a few other brands make them too
This may not be feasible yet business wise, but what about starting up a small overnight shift to maintain machines/production?
Great videos John ! I have to ask what you are using for computers for this programming ? Thank you
I missed that kind of video
John, I know there's a friendly rivalry between you and Mr Saunders, but can I take it from this video that you share his dislike of the SpaceMouse? Personally, I couldn't use Fusion 360 without mine ... 🙂
With regard to the tool path issues, have you considered calculating the necessary thread engagement for the screw, or to put it another way, can you make the screw shorter buy a whisker, or even profile the end of the screw so that it's not clashing with the 140° profile left with by the drill? KISS an' all that.
Nice, tenx ❤️✌️
John seriously your putting off sorting the code, The advice from the podcast, just smile and get on with it - stop procrastinating. 😁
I have taken that advice to my heart, the other day i took all the tote bins down off the wall, washed and relabled them. Only took 6 months. I heard the advice on the podcast, smiled, got the headphones on and just went for it.
why not use a flat bottom drill and skip the endmill all together
Do you balance your tools?
Is there no Gcode that does something like an end current program (basically instantly finish the pallet) that then would drigger the normal pallet change? Something like in arduino code end loop does
I wonder if theres a way to add the logic into the tool call somehow, i've not tried to edit a tool change on Heidenhain but i have edited M6 commands on FANUC machines.
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First!
Bro. We are all getting so old. Fuck.