Aluminium milling problem Fusion Winpcnc

[maud9BSUT]

Hello,

I'm trying to mill a 5mm aluminium piece in 0,5mm steps.

Data:

Spindle speed: 12000

Vadvance: 60mm/min (feed rate on 50%, later on 15%, in both cases problems)

Mill: 2mm diameter, 2 flutes (VHM)

I was wondering if these speeds are okay or not.

I'm also confused about the fact that apparently I have a feed rate in Winpcnc (Vadvance) and in Fusion (cutting feedrate (200mm/min))

The problem is that in the first case (feed rate 50%) my mill breaks and the cut is not smooth, in the second the cut is not smoot and wide. I stopped it before it could brake.

Could you tell me what I do wrong? I'l send you the file with all the information.

Best,

Maud

[seth.madore]

Are you using any cutting fluid, such as coolant or cutting oil? 

[maud9BSUT]

Hello,

I have no coolant. I spray some WD40oil on the mill and the plate (someone advised me to do so).

All the best,

Maud

[seth.madore]

Coolant is going to provide the biggest chance of success, I strongly encourage you to investigate adding that ability to your workflow. Even something as simple as a KoolMist unit

[maud9BSUT]

Hallo,

Apart from the coolant, do you think the rest of the settings are okay?

All the best,

Maud

[seth.madore]

In your toolpaths, you have the spindle speed set to 5000 rpm and a feedrate of 1000mm/min. Do you have to manually adjust the spindle speed on your machine, or does it read the settings in the G-code?

If you are indeed feeding at 1000mm/min, I would say that is much too fast for your tools and lack of coolant. Also, I'd change to a triangular shaped tab, that will greatly reduce tool breakage, as endmills are not at all designed for plunging directly down, in any metal.

[maud9BSUT]

Hallo,

I have to set the spindle manually ( I've set it to 12OOO). What should the feed rate be then?

All the best,

Maud

[seth.madore]

I'm actually running a job in my shop with a 2mm endmill, machining some small slots into an aluminum piece. I'm running at 8k rpm and 3 inches per minute, which translates out to 76mm/min. However, I'm also running flood coolant. I maintain that is going to be the largest contributor to success/failure; coolant. Aluminum is a very sticky material. When it heats up (cutting causes friction, which causes heat), it will weld to anything it comes in contact with, whether that's the tool, or the material itself. The fact that your finish passes have a very poor finish and the slots are too wide are testament to this reality.

[maud9BSUT]

Hello,

Thanks for all the information. I will look forr a coolant solution and try out with the settings you mention.

All the best,

Maud