.....and this is why they are so heavy.

I have stumbled upon this video the other day.

It shows a very good reason to keep those doors closed at all times when runing your machine.

Shrink fit holders and extensions often come with a big through hole.

Its primary use is to allow the shank be knoked out from he back should the tool ever snap off. It is also used to supply coolant for CTS machines.

Unfortunately said hole affects rigidity of the holder making it more likely to chatter leaving bad surface finish and badly affecting tool life.

There is however an old trick to prevent or minimize the chatter.

All you have to do is pack that hole with some thick grease.

Don't forget to cap off the oppening so that grease does not escape when the tool is spinning.

Here are several photos of surface finish before and after grease application. All cutting parameters were exactly the same in both cases.

before. deep chatter marks after. surface finish is ideal tool in extension holder showing capped hole

We all have manufacturer speed & feed charts and have used their recommendations.

But sometimes those charts just don't apply.

For example manufacturer charts assume you are using their endmills at a certain stickout length, flute length and at a certain depth of cut.

But in the real life you rarely match all these conditions.
Sometimes you need to use longer endmill. Sometimes your flute is longer than what manufacturer gave you speeds and feed for.

What i am trying to say is that whenever your real life conditions differ from "normal" you "need to adjust accordingly".
In fact this is what is printed below many charts.

Too bad not many sources tell you how and what to adjust.

While failure to adjust cutting parameters often leads to chatter, poor surface finish and even tool breakage, one of the biggest mistakes people do when machining is

The best online cnc speed and feed calculator FSWizard is now available as an app for iPhone and Android.

CNC Milling and Turning Speed and Feed Calculator For Machinists on the palm of your hand!

Go To FSWizard Online Calculator

Note: Certain HSMAdvisor Licenses Include FSWizard PRO For Android for Free!!
Check out our HSMAdvisor Web Store for Details

Absolutely the best handheld CNC machinist's speed and feed calculator around.
Calculate cutting conditions simply by choosing your work and tool material.
No need to know any numbers. 
FSWizard will automatically use recommended cutting speed and chipload.

* Made by a machinist for machinists * 

Improve productivity and optimize cutter life.

* Milling, Drilling, Tapping and Turning
* Suggests optimum cutting depth and balances cutting parameters.
* Supports Chip thinning and HSM machining.
* Required Power estimation, Recommended Depth/Width of Cut for extra-long cutters.
* Built in tap drill calculator to calculate not only cutting speed and feed , but also drill dia in accordance with desired thread engagement.
* Drill and Tap charts for both imperial and metric systems.
* Oblique Triangle Calculator
* Fillet Calculator will find tangent points to a circle and two lines
* Machinists Bolt Hole Circle and Line Calculators

It just does it all.

*Milling Tools: Solid EndMill, Indexed End Mill and FaceMill, Solid and Indexable drills
*Drilling Tools: Jobber Drill, Hi-Performance Parabolic Drill, Spade Drill, Reamer
*Turning Tools: Profiling and Grooving

Please try the Free FSWizard Lite first to confirm your device capability.
Also huge thanks to those who go through the trouble and leave a review.
Good reviews mean more sales and more incentive for me to further improve on this app.

FSWizard Lite and FSWizard PRO are iPhone/Android machinist calculators that do not require internet connection.
PRO version has all the latest material lists and speed and feed technology.

Lite version has all the same features, but it only has tool steel, mild steel and aluminum in its material list. It still has all the tool types and tool materials found in online and standalone versions
Both Lite and Pro  versions have unlocked tapping data.

Lite versions have limited geometry calculators.

This app is intended not to replace but to complement my much more powerful standalone Windows application called HSMAdvisor.

FSWizard LITE Free
FSWizard PRO $49.99
FSWizard PRO $39.99 Multiplatform License for iOS and Android Purchase through PayPal

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This release features some pretty major updates and features.

First of all, Tool deflection model has been radically improved over previous versions.
Now model fully considers not only the flute length, but also depth of cut and how it affects deflection!

No other speed and feed calculator alows you to do that.

Calculator now helps getting full advantage of those Hight Axial engagement toolpaths.

New things

• HSMAdvisor can now print!
  For now you can print a screenshot of application window. Make sure to select "Album" layout in your printer settings, otherwise portion of the window may get cut off.
  Tool library printing is next in line to be done.
• User Library Export and Import in XML format is now available.
  You can use it to back up your tool library and share library files with others.
• Library Tabs are now right-clickable by mouse- this allows to right click on the library tab and select desired action like "Delete" "Merge" and "Rename".
• Speeds for some tool and stainless steels have been revised.
  Couple of materials were added.

Things updated and improved

• Improved tool deflection model.
• Improved and fixed machine and tool limits trigering.
• Creation of new Tool or Cut now forces newly-created tool/cut to get loaded, so you dont have to search it from the drop-down list- it becomes active right away.
• Viewing and editing of tool/cut info in myCutDB page now does not close opened tool tree.
• Tool material and Work Material are now a single column. Its called Tool&Work Material and it shows tool material for Tool rows and work material for Cut rows

HSM or High Speed Machining is becoming more and more popular each day.
Many of us have seen those youtube videos where endmlls remove large amounts of material at high speeds/feeds.

While definitions of HSM may vary between tool manufacturers and even individual shops, the physics behind it remain the same.

In this article i would like to explore flat endmills.

HSM is not about ramping up your speed/feed overrides to 200% and puling out your smartphone to record another youtube-worth video.

What is HSM?

HSM is a complex of programming, machining and tooling techniques aimed at radical increase of productivity.

Programming

The cornerstone of HSM is low radial and high axial engagement of an endmill with the workpiece.

There are many CAD/CAM systems that allow you to create HSM tool-paths. Mastercam's Dynamic milling and SurfCAM's Truemill are some of them.

When radial cutter engagement with the material is smaller than the radius of the tool an interesting thing happens.
Chip load- the distance the tool advances per cutter revolution per tooth- does not equal the actual chip thickness anymore.
Chip thinning mainly happens at radial engagements below 30% of the diameter.

In order to get compensated chipload you need to multiply recommended by manufacturer chipload by the chip thinning factor.

Usual Radial Engagement for HSM toolpaths however is between 5 and 15%.

Axial depth of cut varies depending on geometry, but

Radial Chip Thinning HSMAdvisor Screenshot

We have alot of stuff coming.

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.

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An attachment like this is sure to save you some time and money running your lathe unattended

And here is a sketch that i used to make it

drawing Side view Front view

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.

Material: D-2 Tool Steel 200-250 HB
Tool: 0.500in 4FL Carbide TiAlN coated Solid HP End Mill
Speed: 360.0 SFM/ 2751.6 RPM
Feed: 0.0023 ipt/ 0.0094 ipr/ 25.76 ipm

Engagement:  DOC=0.330 in   WOC=0.500 in

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