2D contour, Rotary Toolpath

[jeph00]

Good day everyone. I want to try roughing the following roller with a 0.5" endmill in a live tool, and then make a single finish pass with a VNMG insert. 

Can I get the profile of this roller using 2D Contour with a Rotary Toolpath? I have a bunch of these to make out of UHMW, so I want to try roughing it out with a 0.5 flat endmill in an attempt to manage the chips.

Machine is a Mori Sieki NL3000 Mill/Turn Center.

[Anonymous · Accepted solution]

Manage chips by pecking grooving tool.

[jeph00]

Hi @Anonymous . That's a great idea, didn't think of that. I'll give it a go.

Thanks!

[Anonymous]

I mostly use .01 deep pecks, if strings of chips are too long just lower pecking value and repost.

I also like the ability to peck turning passes in confined areas or on plastics and copper, it does wonders for tool life too.

[jeph00]

I've never used pecking with a grooving tool. Its definitely info, I'll keep it in mind.

[jeph00]

Since you seem to have experience with UHMW, what feeds and speeds do you run at when machining this material?

[Anonymous]

Ops, not really familiar with UMHW, I was just saying you can manage chips by pecking groove tool.

I generally feed tool .002 / rev for roughing, adjusting up or down depending on material, tool width and stepover., I slow down for finish pass when fine surface finish is required,

Surface speed is determined by material type, tool rigidity, tool grade / type, machine rigidity and workpiece stability, can't give a number in either case without having global assessment of all conditions, result is compromise between theory,  experience and specific desires or requirements, such as surface finish, cycle time, tool life, cost ... etc.

Start with conservative values, use feed and speed override buttons to determine optimal load and speed then set override buttons back to 100% and adjust your program variables to match those you are happy with.

Some things need gradual increase until signs of trouble surface to indicate red line, often times slowing things down is far more productive then "burn, crash, recover" approach.

[jeph00]

Good advice, I got it running great keeping what you said in mind.