What's new:

• Revised chiploads for smaller endmills.
• Revised recommended Depths of Cut for different material types for endmills with various number of flutes.
• Improved Deflection model to include cutter lead angle.

In this update i have re-visited speeds and feeds area of the calculator.

Recommended Depth of Cut and Deflection calculation was revised.
At the same time Chiploads for endmills smaller than 3mm or 0.125" were reduced in half.

This resulted in most things regarding actual Speeds and Feeds remaining the same, but i believe this update works better as it considers material type and number of flutes to calculate recommended depth of cut.

Also Deflection calculation was changed for tapered endmills

I think it is time to reflect on latest changes to our HSMAdvisor and look at survey results.

Thanks to your input I was able to make changes that I believe addressed some of the issues you guys were having.

You can download and try HSMAdvisor for 30 more days here http://hsmadvisor.com/index.php?page=Download

This update resets your trial counter back to "30 days left", so if your old trial expired, you can use it for one month more.

First of all, I put all of the available overrides on plain sight. Now you do not need to expand a panel to access speed/feed overrides.

I also added cutting speed and chipload to the collapsed view.

Machine Panel now has  Max RPM on collapsed view.

Gages panel now is not expandable and has Read More 

Happy April Fool's day!

Seriously though, i have just published another update.

This update adds a floating Speed and Feed mini-window that stays on top and displays most relevant information to help users with populating S&F values on their CAM software.

To show/Hide this window, click the red-and-white "Float" button in the status bar.

Upon right mouse click on the floating window you can choose what kind of information you would like to display in there.

Also one bug was fixed where when no machine was selected from the drop-down list, deflection and torque limits were not firing for milling and drilling tools.

But wait! There is more!

I will not open all my cards, but right now i am working on a massive update to HSMAdvisor's Tool Database.
Keep tuned in.

Another week another update!

A few days ago a topic popped up in CNCZone's BobCad-CAM forums regarding why speeds and feeds in above mentioned BobCAM were so crazy and unworkable.

Users were complaining and raving about such a "simple" thing like a good speed/feed calculator being missing from there.

This is actually a trend in pretty much any other CAM software package.

They sell tool to create toolpaths.
Many give tools to create 2D geometry and even real solids.

But very few CAM packages offer anything that even remotely resembles working starting cutting parameters.

It does seem bizarre and strange. But every CAM program "knows" type of material being worked on. It knows type of tool, its diameter and length.
It even knows flute length, cutting depth, width, ramp angle... pretty much everything.

But given all that they are unable to combine all this data and produce Speed and Feed that would not either break the cutter or melt it into the work-piece!

Anyway. Back to the topic.

Someone on that forum thread mentioned my old FSWizard.
It sparked quite a lot of interest, and i popped in and dropped a link to the latest version of HSMAdvisor, so that they actually try and see what a good calc can do.

As a result i have received a ton of emails filled with suggestions and thank-yous.

Apparently many did not even know anything about it and were surprised how well it worked for them.
One guy who just bought a license even said that his copy already paid for itself several times over within the first couple of days of using it!

To thank for enthusiasm, i quickly implemented some of those suggestions and i am now releasing them in this version 0.710

New thing are

• Adjustable font size and style. (in Settings) Allows to adjust global application font.
• Adjustable default values for Speed&Feed Overrides, Tool Productivity, Deflection and Torque Limits. (in Settings) You can now set values to which overrides reset by default.
• New Plunge Feedrate field shows up for milling tools.
  Non-Center cutting tools like Indexed endmills etc. will have plunge feed equal Zero.

Thanks everybody for support and suggestions!

As usual you can download the latest release on the Download page.

Happy New Year !

First of all i would like to thank everybody for their continuing support and feedback - without you my work would not be this rewarding and fun.
This holiday season sale has been a success and it is only reassuring me that i am moving in the right direction regarding development of this software.

Also 20 days after the very first release of FSWizard for iOS, sales for it and the Android versions have been going very strong. Which means i will be putting even more effort into improving the mobile versions as well.

New things in HSMAdvisor 0.701:

• Cut and Form taps have been added.
• Boring Bar has been added to the tool type list
• Scallop calculator has been added for ballnose type endmills

Updated and fixed things:

• Effective diameter for tapered endmills (like V-Bits) has been fixed
• Deflection model for endmills has been improved
• BallNose endmills are now considered slotting (floor milling) only when their WOC is set equal to the diameter of the tool.
  When WOC is not equal to the tip Dia, it is presumed the cutter is milling the wall rather than the floor
• Some Tool Geometry fields have been moved to a new tab.

Again after this release i will shift my attention back to mobile versions of FSWizard

Tapping Tool Type BallNose Mill Scallop Calc

Lately there have been a lot of really interesting HSM topics on PracticalMachinist forums.

In one of them a guy who owns his own resharpening business posted a video of his endmill milling a block of D2 hardened to over 60 RC.
The forum topic is located here First try on D2 62Rc(video)

Here is his post so you know what we are talking about:

In the ensuing discussion i posted my own take on how and why HSM works

HSM works in many ways.

1) Reduced cutting time per edge per revolution allows it to cool down more.
2) Chip thinning allows to increase chipload (advancement per tooth per revolution)
3) Increased depth of cut combined with shallow radial positively affects deflection. Tool bends less as it is more rigid towards the tool holder.
4) Higher cutting speed actually reduces cutting forces as heat generated in the cutting zone makes it easier to shear off a layer of metal. Yet because the time of contact is so small, most of the heat is carried away with the chip.
5) Higher RPM also allows to get rid of hot chips faster thus further reducing heat transferred to the tool.
6) Higher feedrate actually reduces relative cutting speed.
7) At high axial engagements more than one flute is in contact with the workpiece at different points along the axis of the tool. This too helps combat vibrations and chatter.
8) You are using more of the tool than just its tip, so technically you can do more work with one tool before it gets dull.
9) lastly it looks cool as hell and is very impressive. Whenever we know visitors or bosses are coming we try to make sure some HSM is going on even if application does not merit that
I am not sure if the air that is moved by the endmill is doing much, but i suspect he didn't mean exactly that.

I have been asked to create a tutorial on how to work with the tool library, so here it is.

myCut Tool Database is quite a unique thing.

It not only contains all of your tools, but also each and every tool can have multiple operations or "Cuts" attached to it.

Everything is very simple.

Database contains Libraries

Libraries contain Tools

And Tools contain Cuts

Each entity behaves according to specific rules and "knows" specific kind of data.

Please read more to learn how it all works.Read More 

I have just uploaded a new release of HSMAdvisor.

I have decided to extend trials every time major releases come out.

This will happen every several months or so.

This release is pretty big. So every one who has not purchased yet gets 30 days more to play with it.

We have material cross-reference tool.

It allows you to quickly figure out material group for a large number of materials. Around 1000 of them.
You can access it by pressing "MORE" button next to material drop-down list.

Here is it looks:

Second Big thing is new tool life estimator.

It allows to show you how tool life reacts to changes in speed, feed rate and depth of cut.

It is a percentage based on normal shoulder milling cut that should equal 100%

Nobody else has this feature- it is absolutely unique to HSMAdvisor and that is in part why i decided to extend trials this time.

Besides tool life gage there is a new tab in results area.

It is called Gages.

It shows important information like what percentage of deflection, torque and machine load we are running at the moment.

It helps to figure out at a glance if something is out of whack.

As always feedback is welcome.

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.

If you are working in mold-making, prototyping or even in a job shop you have had to use unusual form tooling before in your life.

Form tooling is often used to machine undercuts and other features on regular 3 axis machines that would otherwise require a multi axis machining centre or are not machinable o at all.

The classical example of a form tool is a tear-drop ball mil, also known as a "lollipop". It has a tip with a certain diameter and a much smaller shank that produces enough clearance to machine undercuts on straight walls. It can also be used to regular surface finishing and 2d milling.

Another example is a T-slot cutter that is used to produce key-ways and t- slots

The main thing to consider when machining with reduced shank end mils is deflection and torque.

While deflection is especially dangerous for long tools, torque becomes much more important for tools with severely reduced shank.

Torque required to break a tool is directly proportional to the diameter of its shank.

And when shank diameter is much smaller than the tip diameter it does not matter how short that weak portion is: unless you compensate for it you will snap the tool.

The first thing that crosses the mind in many such cases is "I gotta run this tool very slow". It may take forever, but in many cases job gets somewhat done.

Contrary to that many experienced machinists have been proponents of different approach. Instead of reducing feed rate to the point of rubbing and below, it is much more productive to reduce cutter engagement if possible and leave feed rate settings largely unchanged.

Trying to keep proper chip load is even more important when machining work-hardenable materials like stainless steel and titanium. In those cases rubbing is not just unproductive, it leads to a very premature, in many cases instantaneous tool failure.

Just how much of a cut is possible to take in each particular case is the black magic that separates beginners from seasoned pros.

Not to worry though

Here is an example Read More