Tool:0.281 dia 0 helix TIN coated carbide drill

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.

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

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

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:

FSWizard Online is:

FSWizard is here

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:

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

Note: Feed mode must be in G95(IPR)

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

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.

Here are the speeds and feeds for supercobalt minicut end mills.