This release is a major step forward.
We are starting to wander away from just Speeds and Feeds calculator part of the project.

Version 0.022 was a little buggy.

All reported and known bugs have been fixed.

New update version is 0.023

New features:

• Threads page: You can now get thread cutting and tapping data for most popular threads in north America (UNC/UNF/ISO).
  The list of supported threads and features will grow according to necessity and user feedback.
• Machine Profiles now have 2 new buttons: Clone and Import.
  Clone button simply copies selected machine definition with a different name.
  Import button is needed to be able to update/add machine definitions from default machine list. As users modify and customize their Machine List, thay are now able to add machine definitions hassle-free from default_machines.xml file that is supplied with every update.

Bugs Fixed:

• Sticky Ball nose check box

• Max HP improperly rounded

Additions:

• Thanks to Greg Jackson and Matt Doeppers from Tormach i was able to create Horse Power/RPM curves for Tormach PCNC770 and PCNC1100 models (if you install over previous version, you can use import function to add those machines to the list)

Threading Machine Definition Import

Things new in this version:

• Added Lead Angle/Taper Angle/Tip Angle switch that allows to specify the angle of the cutting edge.
• Added V-Bit engraving cutters.
• Added wood materials
• Stainless steels from Medium and Easy groups have been revised.

Tool library changes:

• Tools no longer carry any information about material or engagement- all that extra data is now saved with Cuts
• Fixed a small bug with copy/move function.

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

Quite often in order to start cutting in x-y direction you need to first plunge into the material.

Here is a compliled list of recommendations for different kinds of plunging that works in most if not all cases.

Plunge with center cutting endmill:

• Regular Chipload/Number of flutes , half the cutting speed. (for 3 flute endmill divide normal chipload by 3)

Ramp:

• Ramp Radius (For Helical ramping): .90-.95 of cutter radius

• Ramp Angle: Indexed/non center cutting endmills: 1-2.5 degree; Center cutting endmills- Up to 45 deg

Ramp chipload ajustment for 4 flute Center cutting endmills:

• 0-2.5deg=100% of normal feedrate
• 2.5-5deg=75% of normal feedrate
• 5-15deg=50% of normal feedrate
• 15-30deg=25% of normal feedrate
• 30-45deg=5% of normal feedrate

Dont forget to reduce cutting speed for ramping above 5deg by half!

I have just released HSMAdvisor build 0.017!

First you should uninstall the previous version.
As some of the data files are not compatible with the version 0.017

After downloading and installing it you will receive another 30 days to play with my software.

New things:

• A bunch of new materials
  Structural steels added 1035, 1045 and some other
• Grooving turning tool added to the tool list
• Several Tools and Cuts can now be selected at the same time and deleted or moved to a different Library
• Double click on myCut ToolLibrary now causes the Tool/Cut to load
• HSM Cutting speed compensation now only turns on when HSM/Chip Thinning is checked.
• Huge number of bugs fixed.

Get it HERE ->http://hsmadvisor.com/

Enjoy and don't forget to leave your feedback.
You can do so support forums.

Unfortunately because of high number of spam messages You will have to register first (unless you already did)

Forums are located at http://zero-divide.net/index.php?page=forums&shell_id=170&category_id=1123, a simple registration on my web site (zero-divide.net, register) allows you to post your questions/feature requests/suggestions.

Need i remind you that registered users who actively participate get full version for FREE?

Where do we stand and how did we get here.

When i first started FSWizard project one year ago in December 2011. I felt the need to upgrade my knowledge and skill-set regarding speeds, feeds and best cutting conditions.

Other calculators available at that time simply did not cut it for me.

One of them did not account for such important parameters as tool length.

The other did not care about such crucial tool geometry features like helix angle, shank diameter, lead angle and so on.

As a result i have endeavoured on a mission to build the best calculator that would accurately predict cutting forces, cutter deflection and suggest best cutting modes using all available tool data for multitude of combinations of work-piece/tool materials, coatings and tool types.

It has been a year of research, building cutter and material models, applying REAL MACHINING experience.

All results were tested in REAL PRODUCTION environment.

Today thanks to FSWizard, machines i work on produce 200%-300% more parts per day than 1 year ago.

It has been one year since i have started.
And i believe i have achieved my original goal.

Today The FREE FSWizard gives far better results than many expensive solutions available on the market.

FSWizard:Standalone is the only available program that will warn you if cutter will be reaching its breaking point.

In fact we see paying users of other programs asking their developers for features that have been long implemented in FSWizard.
And we see those developers finally moving out of their comfort zone and trying to improve their program's functionality.

Where do we go from here?

What does the future hold for this project?

No one really knows.
Unlike others who can talk the speed/feed game, I am not into marketing.
I don't do a particularly good job of persuading people that my product is the best thing that happened to the CNC world.

All i have is 2 hours of free time on my hands after work and a ton or real-world machining experience not many in the software business can brag about.

All that remains to say here is

I am not using words "product" ,"consumers" and "business" just by accident.

Next release version of FSWizard:Standalone 0.015 PRO will be a commercial product.

It will be sold as a 1 year subscription.

I am not yet sure about the pricing.
But i know that i will make it subscription-based and the price will be very affordable.

This is the only way to move forward on this.

If you have any comments or thoughts, i would love to hear them out.

Hi-helix end mills have several advantages inherited with their design.

Simple math says that a an endmill with 45 degree helix angle directs 50% of the cutting force downward versus  25% for a 30 degree end mill.

Main advantages are:

• Higher rake angle directs more of a cutting force downward.
  This reduces side load on the cutter, that leads to less deflection and less tendency to chatter.
• At high axial engagement (deeper depths of cuts) more flutes remain in the contact with the work piece. This leads to much smoother cut, again reducing tendency of the cutter to chatter.
• High helix angle pulls chips upward and away from the cutting zone.
  This reduces chip re-cutting and helps prevent cutter from getting clogged up. This also allows to take deeper cuts and increases productivity.
• Because of higher helix more of flute length is being used in the cut. Better surface finish is achieved even when using the same chip load.
  Generally an end mill with 45 degree helix can be fed 30% faster than equivalent one with 30 degree helix and still achieve same surface finish.

High helix end mills also have disadvantages that a machinist has to take into consideration:

• With more of cutting force directed axially, the load on spindle bearings in downward direction is increased.
• Tendency for both the end mill and the work piece to pull out is increased. So a more rigid tool holding and work clamping should be considered.
• Higher helix end mills are also less stiff that regular helix end mills. This may cause more deflection and may become a problem when having to machine straight walls.
  This effect should be mostly diminished by lower side radial load, but it still needs to be considered in some cases.

The ONLY FREE CNC Speeds and Feeds Calcualtor

Confidently calculate cutting conditions for hundreds of work-piece materials and of combinations of tooling types and coatings.

• Accurately Estimate cutting forces involved in machining process and prevent tool breakage.
• Estimate machine power requirement and help choose best tool for the job.
• Suggest safe and practical Axial and Radial engagement values.
• Compensate for reduced-shank, long and extra-long tools.
• Improve cycle times and tool life
• UNIQUE feature that allows to set comfortable levels of cutter torque and deflection and prevent cutter breakage.
• Ideal for use as your Dynamic / Thoroidal / Truemill calculator

Please visit the project page for download link, support and instructions.
http://zero-divide.net/index.php?page=FSWizard_SA

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
Read More 

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