I recently had to machine an aluminum mold cavity.
7 inches deep. With 5 degree wall draft and a 60 thou radius going all the way down. Roughing was not an issue, but for semi-finishing and finishing i had to manufacture these two extension holders.
Both tools have runout of less than 0.001
The one for bigger 3/8 tapered ballnose cutter is shrink fit- i mounted it using torch.
The smaller tool is a 3/32 tapered ballnose cutter from Harvey Tool. I could not bore to correct size, and had to ream right on. The tool is mounted with a set-screw from both sides to prevent deflection caused by unequal clamping pressure.
First of all HSMAdvusor is being particially rebuilt to fix one current issue and provide easier frature implementation in the future. I will try to push update this weekend.
FSWizard:Online has not seen alot of updates in quite some time. A decision has been made to persue mobile web application with bacend running on the server. Currently i am exploring options, modifying mobile version to work with google's jQuery mobile framework to allow seamless deployment across al platforms.
Below is a screenshot of the mobile web app being developed right now.
Some time ago an unknown colleague had borrowed an end mill from me.
Have i had been there i would have stressed that it was aluminum specific cutter and that it should not be used on steel. Unfortunately i was not and it did not occur to him to ask somebody who would have known better.
Next time i look into my drawer i see this.(first picture)
Now we have a tool and cutter grinder to sharpen the OD of an end mill, but chips were so big, i would have to grind off maybe 20 thou of the diameter on order to get rid of them.
Our TC grinder does not allow to re-flute end mills, so i had to do it holding end mill in my hands.
First i picked up correct angle, and then i slide end mill upwards, turning it at the same rate as to follow flutes.
It came out better than i thought. I was not planing to use it for finishing anyway.
And it lost only 5 thou in diameter after this hack-regrinding.
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.
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