Subscribe to Blog
Email Address
 

Real-life examples of machining and Trials.

Pages:(1) [1]

HSM Machining pre-hard 4340 at 900 SFM

September 30, 2016, 7:40 am by Eldar Gerfanov

HSM with MasterCam Dynamic Milling has long been one of my favorite toolpath strategies when machining hardened and tough to machine steels.

The job at hand was to machine out a 5" disk out of pre-hardened 4340 steel. About 43RC hard.
Due to an island in the middle (leaving only 3/4" room for the tool) I could not use a bigger indexed cutter, so i decided to use the adaptive clearing toolpath.

I started out by calculating Speeds and Feeds with HSMAdvisor and come up with the following starting parameters:

Full depth, at 10% engagement.

Which worked just fine. But the tool was not new and I decided to sacrifice it in the name of science and maxed it up to see how long the tool was going to handle it.

So I adjusted the cutting speed to 170% and feed to 150% (which accounts to heavy roughing):

To be honest I was not sure the tool was going to last very long, but it exceeded all my expectations!
It lasted for about 2 hours and completed the whole run of more than 20 pieces.

I even took a video cutting one of the parts:

Note how there are no sparks coming out. This is because the chip is thick enough to not overheat. This works both ways. Chips stay cool and due to their larger mass carry most of the heat away from the cutting edge.

After the end of the run (and it was not new to begin with) the tool looked like it could do as much!


Rev Up Your Tools - Boost the Productivity!

July 15, 2016, 10:59 pm by Eldar Gerfanov

As unhappy I am to learn that something may be wrong with the software I develop and love, negative feedback is essential in learning whether i am doing everything right.

So a couple of days ago I received an email from a somewhat disappointed user. 

He (lets call him Peter) was complaining that HSMAdvisor calculator gave him "excessively high" speeds and feeds for his 3/4" 4 flute 3.0 LOC  end mill in aluminum.

With the data Peter entered he was getting around 10000 RPM(SFPM 2117) and the feed of 270 inches per minute while usual practice in the shop was side-milling aluminum at that (2.8" axial) depth at only 325 SFM

After double-checking the numbers I replied that in fact his numbers seemed very slow and if for some reason he HAD to run that slow (heck, i machine most steels faster than 325 SFM) due to some conditions, perhaps, he was ought to change the conditions themselves.

This is what I am getting for Peter's end mill setup:

...
...Read More


Best High Speed Machining is Dry Machining

May 18, 2016, 10:06 pm by Eldar Gerfanov

Ever wondered how much tool life can deteriorate when using coolant with High Speed Machining (HSM)?
Or maybe you never really saw the boost in tool life when using HSM techniques because you had to use coolant?

Well here is a test results I just got from running the same tool at the same Speed and Feed with and without coolant.

...
...Read More


One Case of HSM Machining: HSMAdvisor vs. All

April 2, 2016, 7:41 pm by Eldar Gerfanov

Look for the HSM machining of the round central pocket in the beginning.
Here we have a 12mm 6 flute Coated hi-performance endmill, cutting 1" deep at 0.047" (10%) rWOC.
at 10000 RPM and 300 ipm feedrate. the chipload works out to be 0.005". Material is 4140 pre-hardened steel.

Impressive isn't it?
Those results have been achieved with uber-expensive BlueSwarf tap-test technology.

This is one video that caught the eye of one of my HSMAdvisor trial users:

 

Being a geek and wanting to help the user make the right decision I immediately punched the numbers into my HSMAdvisor app.

Here is what I've got:...
...Read More


Machining 4140 PH Speeds and Feeds

December 10, 2015, 4:10 pm by Eldar Gerfanov

Sometimes I get asked whether hsmadvisor CNC Machinist Calculator is reliable enough out of the box.

I and many others test it at work every day. This 2"x1.5"x1.25" 4140 PH piece was programmed on masterscam with hsmadvisor speeds and feeds with all overrides set to default.

Worked out fast and awesome. As usual!


14497779489640.jpg 14497779489640.jpg

Successful High Speed Machining (HSM) Stainless Steel Part

November 28, 2014, 10:54 pm by Eldar Gerfanov

A couple of days ago I helped a gentleman by answering a few questions about using HSMAdvisor Speed and Feed Calculator to machine a 310 Stainless Steel piece using HSM techniques.

Today he created a post on PracticalMachinist forums walking us through his experience.
And he even took a video of the part being cut!

Quote:KROVVAX
I would also like to say thanks to zero_divide for the help he gave me with the speed/feed and after using is HSMadvisor i suggest to everyone to give it a try its really worth it.

Endorsements like this is the best thing any software developer can hope for.

I always welcome any feedback regarding my software and never mind helping anyone, whether he is a novice, experienced machinist, my customer or not.

Thank you Sebastien, good luck to you!

 


Niagara Elite HP 3 flute Hi Performance Endmill Test

September 18, 2013, 12:22 pm by Eldar Gerfanov

Here is a video of a 3 flute Hi-performance endmill slotting aluminum 0.75" deep per pass.

Well, not entirely slottimg, more like pocketing, but the very first move is a full width slot.

Stepover is 0.4"

First i calculated the cut on HSMAdvisor.

Used 6061 aluminum as material and HP endmill at a tool type.

Tool torque and deflection limits were both set at 100% and performance slider was at maximum.

This is what it came up with:

S9127 RPM 125 IPM.

Full slot, 0.75" deep.

45 in^3/min mrr.

Looking at how easy it went i think i should allow for more load in my calculator.

If you have not yet tried HSMAdvisor, make sure you do.

You will be amazed at how much productivity you have been missing out on.


Pre-Hard Stainless & HSM Advisor Test

May 19, 2013, 12:37 pm by Eldar Gerfanov

Sevaral weeks ago i saw a post on CNCZone.

A HSMadvisor user Peter Neil used it to calculate cutting conditions for cutting a block of pre-hardened stainless steel.
His machine was Tormach.

Here is an exact copy-paste from that forum post:
_____________________________________________________________________________________

Did a test cut on the Tormach today using feeds & speeds from the latest version of the excellent HSM advisor.
To make it interesting, I did the cut using some 1.2085 pre-hard Stainless Steel as I have plenty of stock of it and have a job in mind for this, and wanted to see how it cut on the Tormach.
The material is like a stainless P20, at 16% Chrome/1% Nickel & 0.5% Sulphur (which makes it slightly free-er machining) and is hardened to around 33-35 Rockwell C, so I used the HSM advisor guidelines for machining P20 rather than Stainless. Cutter was a 10mm 4-flute Carbide TiAlN coated EM.

So...... ticking the HSM/Chip thinning option I got a speed of 5120 and feed of 2214mm/minute( 87 IPM). I used a DOC of 10mm and WOC of 0.5mm/0.020" - and turned off the flood cooling to machine it completely dry. The finish pass on the 1st level was 15mm DOC and 0.5mm WOC and slightly lower speeds/feeds.

Loaded up a 40mm x 63mm block , pressed the start button, and it went from this....





...to this!

...
...Read More


Why do we machinists need a feed and speed wizard

February 14, 2013, 10:44 pm by Eldar Gerfanov

Sometimes people ask me: "I tried your calculator, and i liked it, but it seems to me a little too aggressive...do you actually do any testing?"

Well, to those I say that not only i do testing, but i run production jobs 100% calculated with my own HSMAdvisor.

Many machinists say that nothing beats an experienced operator holding his hand on feed hold button and playing with speed and feed override trying to find the "sweet spot" where cutting speed and feed rate are maximized and chatter is eliminated or reduced.

And it is correct, but not any machinist is experienced or actually knows what he is doing.
Many machinists also finish their apprenticeship program and never learn a single thing about new tooling types and materials since. They bag years of experience, but their knowledge is stuck on a level it was when they first got their license.

Also not a single person can possibly know cutting conditions for hundreds of materials and remember all of the jobs he had ever ran.

This is where tool database comes in.

Not only can you save tools to cut down and in many cases eliminate entering parameters for every calculation.
But you can (and should) save cutting data for each particular case.

A single tool entry can contain an unlimited number of cuts attached to it, so machinist never has to remember everything.

Here is a i made video of slotting D2 with variable helix hi-performace endmill.

Material: D-2 Tool Steel 200-250 HB
Tool: 0.500in 4FL Carbide TiAlN coated Solid HP End Mill
Speed: 360.0 SFM/ 2751.6 RPM
Feed: 0.0023 ipt/ 0.0094 ipr/ 25.76 ipm

Engagement:  DOC=0.330 in   WOC=0.500 in


Roughing A36 Hot Rolled Steel with speeds and feeds by FSWizard

January 27, 2013, 11:54 pm by Eldar Gerfanov

Speeds and Feeds by HSMAdvisor (FSWizard)
Material: A-36 Hot Roll Steel 160-220 HB
Tool: 0.500in 4FL Carbide TiAlN coated Solid HP End Mill (WIDIA Metal Removal Maestro)
1" Stickout, 0.625 Flute Length
Speed: 528.0 SFM/ 4035.7 RPM
Feed: 0.0028 ipt/ 0.0114 ipr/ 46.00 ipm
Chip Thickness: 0.0028 in
Engagement:  DOC=0.250 in   WOC=0.500 in


Pages:(1) [1]

© 200908:53:46-2016 Eldar Gerfanov. All Rights Reserved.
© 2009 Eldar Gerfanov. Materials on this site are presented as is and are mostly for educational use. You may freely reproduce information presented herein without any consent from me, provided you include link to this site.
In case when i am not the copyright holder, you may want to contact proper owner of material. Anyway, they are freely available on the Internet.
If you hold the copyright right for any of the materials on this site and want them removed, please contact me here