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FS Wizard: Dormer Drill test on T6061 Aluminum

April 23, 2012, 8:22 pm by Eldar Gerfanov

As part of FS Wizard's development. 2 drills were tested today on T6061 Aluminum.

0.312 Dia and 0.390 Dia Dormer A002 Drill Jobber Drill with TiN coated tip.

Helix:30Deg

Point:Split, 118Deg.

Hole depth for both was 3.0"".

Peck equaled 1xDia

Speeds and Feeds for 0.312 Dia drill were

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Drilling Hardox 500 55RC: 0.281 dia .75 deep

April 20, 2012, 1:47 am by Eldar Gerfanov

Tool:0.281 dia 0 helix TIN coated carbide drill

Peck:0.125

Coolant: Air

RESULT
SFM: 49 f/min
RPM: 663
APT:  0.00070 in/rev
Feed: 0.93 in/min
MRR: 0.1 in^3/min
HP: 0.2
Torque: 19.4 in-lb
Max Torque: 22.9 in-lb

 


Test of NIAGARA 3FL HP End mill for Aluminum

February 27, 2012, 11:02 pm by Eldar Gerfanov

Recenty ordered a 3Flute High Performance End Mill From NIAGARA.
Was very glad and slightly surprised that when punched in all of the endmill's data into my Calculator nothing broke down.I had a rason: At 5000RPM and 3/8" Deep slot cut. The feed came to around 92.0IPM. Chips were making this nice ringing noise that sounds like money.

Setup:
HAAS VM-3
Hudrolic Tribos Holder
3/4" 45DegHelix 3Flute 1.625FluteLen, 2.375"Overhang TICN HP End mill

S:5000RPM
F:92.0IPM
DOC: 0.375" Slotting
Coolant:FLOOD

The calculation was pretty much dead on.


Tapping Hardox Rc 45-50

February 27, 2012, 10:43 pm by Eldar Gerfanov

A need arouse to drill and tap lots of blind 1/4-20 holes in 3/4" thick hardox 45-50RC hard plate.

So if you ever need to do this use:

1) DRILL
Tap hole: >0.202" or bigger.  5/8 deep.
Drill used: Tialn coated carbide drill.
S=1418 RPM
F=2.6 IPM
NO Peck, No Coolant

2)TAP
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Renishaw OTS tool probe cycle for HAAS can set both length and diameter offsets.

Too bad there is no choice: it only puts absolute measured diameter of the tool into D- diameter offset and makes wear offset=0

But if your programming is done with the center of the cutter, then you actually only need the difference between actual and programmed diameters of the tool.


I.E.: When probing 5/8Dia end mill, we get D=0.6248. You would normally have to subtract 5/8 from it and leave the -0.0002 difference.

But there is an easier way

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HAAS: Making G54-G59 show Z0 at the top of fixture

November 29, 2011, 11:50 pm by Eldar Gerfanov

Problem: Work offset G54 Z0 shows some "weird number" which is very hard to relate to.

Can we make top of fixture show Z0=0.000 ?

Solution:

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FSWizard: Online CNC Machinists Calculator

October 14, 2011, 9:33 pm by Eldar Gerfanov

FSWizard Online is:

It is the most accurate Online Feeds and Speeds Calulator.

In order for every user to enjoy latest modifications and most accurate results, it is WEB Based.
This means that you can use it across all imaginable operational systems and devices.
All you need is an internet connected WEB browser.
No download or installation is required: Just visit the web page.

Also a full functioning mobile version is available.

Key Features of FSWizard:

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Thread Turning on Okuma

March 7, 2011, 1:26 pm by Eldar Gerfanov

G71 X Z A|I B D U H L E F J M Q

  • D=First Depth of Cut
  • U=Finish Depth of Cut
  • J=Number of threads at F
  • X=Target Depth (minor Dia of theread)
  • Z=Coord of end Point
  • A= Angle of thread
  • B= Tool Cut angle
  • H= Difference between major and minor dia of the thread
  • M= Cut pattern
  • M32= Longitudal
  • Q= Number of leads

Code
N24 (T5 OD 60DEG CW THREAD TOOL)
N00 G97 G95 S300 M3
N01 G0 X2.1 Z3.05
N02 M8
N03 G0 X1.2
N04 Z0.1538
N05 X0.7
N06 G1 X0.5 F0.076
N08 G71 X0.4 Z-0.8269 D0.01 U0.003  B29. H0.05 F0.077 M32
N09 G0 X1.2 Z-0.8269
N40 Z3.05
N41 X2.1

Note: Feed mode must be in G95(IPR)


Milling Hardox Steel Rc 45-50

January 26, 2011, 11:17 pm by Eldar Gerfanov

Out Company used to have somebody else plasmacut cutting anvils for us.
This was expensive, plus heat generated by plasma caused already unstable anvils to warp like crazy making them very hard to grind flat.

So when foreman told me to machine one on CNC i immidately asked him to buy one of those nifty Hanita TiALN coated Varimill cutters.
Too bad they are too expensive. So the company bought same style of cutters made by Niagara. 0.5" end mill there is x3 cheaper than hanita's. Plus i believe cutting tools made to the same specs, out of the same materials are performing identical.

The machine we ve been using for this is really shaky and busted, so dont laugh at speeds and feeds that we came up with.

So basically, Specs Are:

  • Material: Hardox pre-hardened steel Rc 45-50
  • Cutter: 4 Flute, Stagger Flute TiALN coted 0.5" Micrograin Carbide End Mill, 2.5" Overall, 0.625" Flute Length, 1" overhang
  • Operation: Slotting
  • Speed: 1200 RPM
  • Feed: 4.8 IPM
  • Depth OF Cut: 0.125"
  • Plunge method: 2.5 Deg Ramp/Helix, Or Plunge into 0.281Dia pilot hole at 3 IPM
  • Coolant: Airblast + Oil

Drilling Hardox steel Rc 45-50

January 26, 2011, 11:16 pm by Eldar Gerfanov

Lately we've been doing alot of anvils out of 3/8 or 1/2" Hardox steel (Rc 45-50)
Aside from having to machine profiles and pockets we also have to drill some mounting holes.

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