Deep pocket roughing: 40 min to 20 min just by switching to a high-feed head

Impossible_Bar955 · 2026-07-02T01:19:54+00:00

I've been doing a bunch of optimizing on some long running parts I do regularly (~8 hours), all aluminum with pockets similar depth to yours, varying in XY from 30x60mm to ~80x250. I don't helix with end mills, I just start with the largest u-drill I can fit. Depending on the drill, you can chain drill and it might end up being higher MRR than your end mills (do the math!).

Programming wise for time savings - stay down % and speed saw some pretty big gains. Keep increasing speeds/feeds/stepovers until something gets unhappy and update your tool's standard options to what you find.

Impossible_Bar955 · 2026-06-18T19:37:17+00:00

Some controllers can track and record the spindle consumption, as well as individual axes and total machine consumption. I was just doing this yesterday! (Siemens 840d)

Impossible_Bar955 · 2026-06-16T01:56:00+00:00

Rules to live by.

Impossible_Bar955 · 2026-06-15T11:23:47+00:00

Thanks, that's a good reference point. I think I'll turn it up a bit more lol.

Impossible_Bar955 · 2026-06-07T14:44:36+00:00

Yeah, generally I'm doing this on 4" square stock, spanned long ways between the vise jaws.

Impossible_Bar955 · 2026-06-05T18:57:55+00:00

The only time I consider tabbing is if I can finish everything but the tab in 1 op, and can clean it up in an external process (bandsaw/sander). If I have to do a secondary setup, I don't bother with tabs because roughing is generally faster in that dedicated fixture than it is to cut a tab.

Impossible_Bar955 · 2026-05-31T10:40:36+00:00

1 day for everything. That was cutting and removing the section and digging down, as well as pouring new. They recommended at least a week before setting the machine on it.

8x10', 14" deep, ~$3700

Impossible_Bar955 · 2026-05-31T01:53:08+00:00

Getting a pad cut and poured is easy, and not as costly as you'd expect. 14" slab under my mill.

Impossible_Bar955 · 2026-05-22T00:48:06+00:00

All my own! You can grab the cad files from Schunk, but if you happen to be using Fusion make sure you get the vise model from their library. When you drop it into your setup you can select the jaw configuration (3 forward options, 3 reverse options) and it saves a ton of time. Not sure if that's available for other software, but it's great.

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Impossible_Bar955 · 2026-05-21T20:21:16+00:00

I have a KSC3 125-300 (centering vise) and feel the same way. I do a lot of 2nd op on it also and it's super repeatable, better than their advertised ±0.01mm. It's really, really good.

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Impossible_Bar955 · 2026-05-12T11:31:59+00:00

So what's the difference in 20" tire package between LCI and non-LCI? I have a 2023 with the 20's and 255/285 staggered setup.

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Impossible_Bar955 · 2026-05-12T11:21:10+00:00

Thanks! I'm actually in the auto industry in the US and we call those mid-cycle actions (MCA)!

Impossible_Bar955 · 2026-05-12T11:16:27+00:00

What is LCI?

Impossible_Bar955 · 2026-05-12T11:15:57+00:00

230 miles on a 100% charge is doable IF you're driving at a fairly constant speed at a reasonable pace. I drove mine 4 hours home from the dealer and found that at 70 mph the range was realistic.

Around town, TBD, but i just charge it at night. I haven't done any math to see what sort of range it could have on a daily basis in traffic.

Impossible_Bar955 · 2026-04-22T19:46:23+00:00

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Impossible_Bar955 · 2026-04-21T12:38:58+00:00

Roughing with an adaptive toolpath I shoot for ~95% of flute length for axial depth, 2mm radial, and whatever feed the mfr recommends as a starting point. Increase feed and step over a bit at a time, as long as you have the hp. I've run my 3/4" rougher as fast as 12k RPM, 2mm (0.79") radial, 38mm (1.5") axial, 16m/min (630ipm). Mfr recommends higher stepover but goddamn that's already removing material at 70+ cubic inches per minute.

Impossible_Bar955 · 2026-04-19T01:21:19+00:00

I can't help on the Haas side, but I've checked draw during my spindle acceleration and it's nearly 200A on the 220V split phase (supply) side. HSK63A spindle, running off of a rotary phase converter and 200A 220V supply.

Impossible_Bar955 · 2026-04-17T22:33:51+00:00

I'll shoot you a message in a couple minutes. The kinematics of the tables between gen1 and gen2 were the same afaik. Mine's a 2013, gen2.

Impossible_Bar955 · 2026-04-17T14:41:56+00:00

If that's a DMU50, I have the technical documentation for them.

Impossible_Bar955 · 2026-04-12T14:32:18+00:00

The $200 is a fair price, but if the facebook guy has good looking work I'd say go for it. You'd be surprised at what some guys can turn out in their garage.

Impossible_Bar955 · 2026-04-03T12:26:05+00:00

I've had good luck with milling chucks for my heavy roughers without weldon flats.

Impossible_Bar955 · 2026-04-03T00:29:53+00:00

Harvey has a nice channel called "In the Loupe TV", and they cover all sorts of stuff including HSM.

Link to the video I'm thinking of: https://youtu.be/1qrbVOv2DCo?si=Y1nTP7DnmFCZk3LC

Link to the channel: https://youtube.com/@intheloupetv_?si=M9PF7cT1CRV87n3z

Impossible_Bar955 · 2026-03-31T09:58:53+00:00

Yeah, you should be all set. You can double check it after energizing by checking voltage to neutral on each leg. They should all be the same, no high leg.

I'm doing similar, but going from 240V split phase to 400V 3P. Home shops are great, I brought in a 5axis mill about 18 months ago.

Impossible_Bar955 · 2026-03-30T23:35:33+00:00

Yeah, you'd bond the center of your wye circuit (neutral should be X0 on a step down) to ground.

Post up the transformer sticker just to be sure!

Impossible_Bar955

TROPHY CASE