HSM with MasterCam Dynamic Milling has long been one of my favorite toolpath strategies when machining hardened and tough to machine steels.

The job at hand was to machine out a 5" disk out of pre-hardened 4340 steel. About 43RC hard.
Due to an island in the middle (leaving only 3/4" room for the tool) I could not use a bigger indexed cutter, so i decided to use the adaptive clearing toolpath.

I started out by calculating Speeds and Feeds with HSMAdvisor and come up with the following starting parameters:

Full depth, at 10% engagement.

Which worked just fine. But the tool was not new and I decided to sacrifice it in the name of science and maxed it up to see how long the tool was going to handle it.

So I adjusted the cutting speed to 170% and feed to 150% (which accounts to heavy roughing):

To be honest I was not sure the tool was going to last very long, but it exceeded all my expectations!
It lasted for about 2 hours and completed the whole run of more than 20 pieces.

I even took a video cutting one of the parts:

Note how there are no sparks coming out. This is because the chip is thick enough to not overheat. This works both ways. Chips stay cool and due to their larger mass carry most of the heat away from the cutting edge.

After the end of the run (and it was not new to begin with) the tool looked like it could do as much!

Just saw this very impressive machining video on Practical Machinist forums.

A very nice example of using machine and the tools to their full potential.

Huge "Farewell to MasterCAM x9" HSMAdvisor Hook update has been released.

The MC 2017 has been out for a few month now and because it has received quite mixed reviews from the machinist's community, i decided to release one more big update to our MCx9 hook before starting to fully work on adapting it for MC 2017.

This update v1.402 is a double update. The hook version has now caught up to the standalone AND we have some new features in standalone HSMAdvisor as well.

Here is a quick video showcasing most of the new features:

What is new and improved in this HSMAdvisor update

• New Hardened D2 and M2 Steels
• New 17-4 and 13-8 Stainless Steels in various conditions
• Mew DB Contents Tree in Select Tool Dialog
• Plunge Speed Lock
• New Free GD&T Reference Tab
• Updated Look and functionality of Scientific Calculator
• Updated look of all Geometry Calculators.

Whats new and improved in HSMAdvisor Hook:

• Improved Toolpath import and export
• New Improved Select Tool/Cut Dialog with Side Contents Tree
• Plunge RPM lock for toolpaths, that do not support Plunge RPM different from the main RPM
• Ability to choose which data is read and written into the toolpath.
• Full ToolDB Functionality including editing and saving tools is now free.

As usual Here you can download the latest updates: http://hsmadvisor.com/ 

Questions, troubles? Let us know via email or our support forums!

Regards. 

As unhappy I am to learn that something may be wrong with the software I develop and love, negative feedback is essential in learning whether i am doing everything right.

So a couple of days ago I received an email from a somewhat disappointed user. 

He (lets call him Peter) was complaining that HSMAdvisor calculator gave him "excessively high" speeds and feeds for his 3/4" 4 flute 3.0 LOC  end mill in aluminum.

With the data Peter entered he was getting around 10000 RPM(SFPM 2117) and the feed of 270 inches per minute while usual practice in the shop was side-milling aluminum at that (2.8" axial) depth at only 325 SFM

After double-checking the numbers I replied that in fact his numbers seemed very slow and if for some reason he HAD to run that slow (heck, i machine most steels faster than 325 SFM) due to some conditions, perhaps, he was ought to change the conditions themselves.

This is what I am getting for Peter's end mill setup:

One of HSMAdvisor users asked me for help figuring speeds and feeds for machining stainless on his underpowered Tormach 700.
He volunteered to send me a model to work on, so I decided it was a good opportunity to make a learning video and share it with everybody.

I must say programming for such a low-power machine is a lot harder than for a full-blown production VMC where you are not worried about stalling your machine with anything under 1" in diameter:

Your thoughts and comments are always welcome.

We are actually listening to our users!

We all know what the CNC Milling Machine spindle is used for - to hold the tool. But it is old and boring. Everybody does that.

Here are the 6 interesting and maybe less common ways to utilize machine spindle, increase productivity and solve some problems you never thought you had.

Use your Spindle as a fan to blow chips and coolant off of your work-piece, table and fixturing.

I saw this little gadget at a local IMTS show and it was quite cool. It is installed into a tool holder like a regular cutting tool would be and at the end of the program you can call the it up and run a little table-cleaning program to make your work a lot cleaner!

Latest advances in tool technology make milling of high carbon and tool steels as reliable and predictable as benign aluminium alloys.

In this video a large 4140 steel component is being roughed out at 2700RPM and 600 inches per minute.
While achieving  impressive material removal rate (20 pounds of steel machined off in a matter of half an hour!) the tool life puts the old school square shoulder endmills to shame.

Yes, it could(and should) have been machined using a bigger cutter, but I wanted to put the tool to the test.
And it performed beautifully: Was able to surpass the recommended starting speeds and feeds by at least 170%!

Look for the HSM machining of the round central pocket in the beginning.
Here we have a 12mm 6 flute Coated hi-performance endmill, cutting 1" deep at 0.047" (10%) rWOC.
at 10000 RPM and 300 ipm feedrate. the chipload works out to be 0.005". Material is 4140 pre-hardened steel.

Impressive isn't it?
Those results have been achieved with uber-expensive BlueSwarf tap-test technology.

This is one video that caught the eye of one of my HSMAdvisor trial users:

Being a geek and wanting to help the user make the right decision I immediately punched the numbers into my HSMAdvisor app.

Here is what I've got:

Being a professional CNC Machinist myself with a good manual background I often find myself watching various machining videos and blogs.

Unlike others I do not often share somebody-else's work, I could just not walk past this one and not tell everybody how great I think this is....

This story was posted on "Russian reddit" and here is the direct translation of the author's post:

Lets begin with tyres. Vladimir (guy's name) decided to create the mould to make the rubber tyres himself. Here it is:

Here are the tyres he made with it. Beautiful aren't they?

He also made little differentials. Housings, gears. Everything made himself:

I personally use HSMAdvisor at work every day and trust its results 100%

I have to say my program now knows about machining more than i do. I certainly can not remember cutting speeds and feeds, reduction factors, depth of cut and a ton of other information for every material I have ever cut.

Now add to that the various possible combinations of tool/material/coating and it becomes a no brainier, that a good speed and feed calculator like HSMAdvisor saves a ton of time and money by improving your tool life and productivity.

It is not only good for HSM (High Speed Machining) but also for general machining, drilling tapping, you name it.

The algorithms it employs are far superior to what other calculators are using. Take for example the real-time depth of cut/deflection optimization, that other calculators do in a separate window and take a few seconds to complete.

Here is a quick video lesson where i show the steps involved in creating a simple contouring toolpath in MasterCam x9:

And here is the video of machining the actual part: