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
- T-800 by Eldar Gerfanov on January 3
- Importing HSMWorks Tool Libraries into HSMAdvisor by briankb on September 14
- Announcing HSMAdvisor 2! by Eldar Gerfanov on July 24
- Programming Efficient Peck Drilling Cycle by Nguyen Van Du on March 30
- Calculating Tool Engagement Angle, Radial Depth of Cut by Hank on January 31
Speeds and Feeds by HSMAdvisor (FSWizard)
Anybody could use a pair (or more) of push clamps around their shop.
Those handy devices convert your machine' table into a huge vise.
They are pretty mush irreplaceable when machining plates and other oversized parts that no ordinary vise will fit.
Several vendors offer their clamps. But many of them tend to be pricey. And those that are not, lack in quality.
And to be honest with you, it does not look like they are worth the amount of money their seller is trying to get from you.
In the mean time their design is simple enough to fabricate in any shop.
Here is a picture of two of four clamps i made for myself on manual mill withing 2 hours- sure beats buying mitee-bitees for 175$ a pop!!!
Made out of 5/8" thick D2 plate
1" long Shoulder in the front is tapped to 3/8-16 NC.
Slot for 1/2-13 bolt is sloped towards the back to prevent clamp from sliding under clamping pressure.
A thick 1/4" washer is used to protect T-slot from damage by the socket head.
I ll try to get more pictures tomorrow.
FSWizard:Online has a new feature.
Thanks to a suggestion made by Kennis on Suppport Forums we now have basic thread milling speed/feed online solution.
Take it for a spin guys.
If you have anything else to say regarding this feature, or maybe some suggestions please reply to this forum thread http://zero-divide.net/index.php?page=forums&shell_id=170&article_id=4280
And keep your suggestions rolling!
Where do we stand and how did we get here.
When i first started FSWizard project one year ago in December 2011. I felt the need to upgrade my knowledge and skill-set regarding speeds, feeds and best cutting conditions.
Other calculators available at that time simply did not cut it for me.
One of them did not account for such important parameters as tool length.
The other did not care about such crucial tool geometry features like helix angle, shank diameter, lead angle and so on.
As a result i have endeavoured on a mission to build the best calculator that would accurately predict cutting forces, cutter deflection and suggest best cutting modes using all available tool data for multitude of combinations of work-piece/tool materials, coatings and tool types.
It has been a year of research, building cutter and material models, applying REAL MACHINING experience.
All results were tested in REAL PRODUCTION environment.
Today thanks to FSWizard, machines i work on produce 200%-300% more parts per day than 1 year ago.
It has been one year since i have started.
And i believe i have achieved my original goal.
Today The FREE FSWizard gives far better results than many expensive solutions available on the market.
FSWizard:Standalone is the only available program that will warn you if cutter will be reaching its breaking point.
In fact we see paying users of other programs asking their developers for features that have been long implemented in FSWizard.
And we see those developers finally moving out of their comfort zone and trying to improve their program's functionality.
Where do we go from here?
What does the future hold for this project?
No one really knows.
Unlike others who can talk the speed/feed game, I am not into marketing.
I don't do a particularly good job of persuading people that my product is the best thing that happened to the CNC world.
All i have is 2 hours of free time on my hands after work and a ton or real-world machining experience not many in the software business can brag about.
All that remains to say here is
I am not using words "product" ,"consumers" and "business" just by accident.
Next release version of FSWizard:Standalone 0.015 PRO will be a commercial product.
It will be sold as a 1 year subscription.
I am not yet sure about the pricing.
But i know that i will make it subscription-based and the price will be very affordable.
This is the only way to move forward on this.
If you have any comments or thoughts, i would love to hear them out.
Download link to the standalone version has been removed ahead of a major release planned this month.
We have decided to not keep a version vastly inferior to the next one available for download any longer.
Sorry and check back in a short while.
Here are some samples of nested parts i did recently
In both cases back of all pieces were machined at the same time, dowel holes milled so that there would be a way to align top and bottom.
Ealot of material was lost, but it was a scrap anyways, so all i gained was alot of saved man-hours.
And here are 4 more pictures:Read More
So how do you guys like it.
Give me a shout!
Hi-helix end mills have several advantages inherited with their design.
Simple math says that a an endmill with 45 degree helix angle directs 50% of the cutting force downward versus 25% for a 30 degree end mill.
Main advantages are:
- Higher rake angle directs more of a cutting force downward.
This reduces side load on the cutter, that leads to less deflection and less tendency to chatter.
- At high axial engagement (deeper depths of cuts) more flutes remain in the contact with the work piece. This leads to much smoother cut, again reducing tendency of the cutter to chatter.
- High helix angle pulls chips upward and away from the cutting zone.
This reduces chip re-cutting and helps prevent cutter from getting clogged up. This also allows to take deeper cuts and increases productivity.
- Because of higher helix more of flute length is being used in the cut. Better surface finish is achieved even when using the same chip load.
Generally an end mill with 45 degree helix can be fed 30% faster than equivalent one with 30 degree helix and still achieve same surface finish.
High helix end mills also have disadvantages that a machinist has to take into consideration:
- With more of cutting force directed axially, the load on spindle bearings in downward direction is increased.
- Tendency for both the end mill and the work piece to pull out is increased. So a more rigid tool holding and work clamping should be considered.
- Higher helix end mills are also less stiff that regular helix end mills. This may cause more deflection and may become a problem when having to machine straight walls.
This effect should be mostly diminished by lower side radial load, but it still needs to be considered in some cases.