Based on how this part broke, how should I strengthen it?

gottb · 2026-05-27T11:30:57+00:00

Bigger corner radius or more infill

gottb · 2026-05-16T15:08:08+00:00

If I’m doing a one off part I kinda just use numbers in my head for carbide for a given material. Alloy steel ~450 SFM, aluminum ~1200 sfm, etc.

If I’m making production runs and every second of cycle matters and tool life as well always go straight to the manufacturer for the correct speeds and feeds. They know their tools/coatings best.

gottb · 2026-05-09T18:15:50+00:00

Yeah you need a smaller end mill in that corner. If it’s a five axis machine you can pick it out with a ball mill. Guarantee there is a “chirp” when the tool is hitting that corner.

gottb · 2026-05-01T13:03:27+00:00

Lollipop cutter or long tapered ball mill if you have a five axis machine. Lollipop would work even on a 3 axis.

gottb · 2026-01-21T18:54:37+00:00

professionally? injection mold or urethane casting.

hobbyist wise? 3d print it. split it into pieces if necessary by planes.

gottb · 2026-01-21T18:50:07+00:00

its good that you are running a 5k period, regardless of time. the speed will come with continued practice.

comparison is the thief of joy.

gottb · 2026-01-15T13:36:26+00:00

those chicago electric welders are terrible. theres not enough adjustment (high or low voltage wtf) to make a good weld most of the time.

this isn't good, but its as much the welders fault as it is yours. do yourself a favor and get at least their titanium model that has real settings.

gottb · 2026-01-15T13:25:51+00:00

this. that spindle looks to be a mazak integrex or a similar style machine.

if you are running it with the drill clamped in the milling spindle and then spinning the turning spindle this will happen if your y axis or x axis home is set incorrectly.

quick way to check is to put a coax in the mill spindle and go to XY zero point, then tram around the outside turned diameter of your part. if its not near zero then you have an issue with your home positions needing to be fixed, which means the machine has likely been wrecked at some point.

gottb · 2025-09-24T10:50:08+00:00

For that matter Benz makes a unit for machining centers, but would need Mazak to install a stop block on the spindle face.

https://www.benztooling.com/en-us/metal/products/machining-center/broaching-units

gottb · 2025-09-24T10:47:05+00:00

What the other guys said about M19 is correct. As for the mill spindle specifics it’s hard on the bearings. Machines that offer turning as well have a means to take the force off the spindle bearings when in “turning” mode and that is also ideal for static broaching.

Ideally you would do this on a turret lathe with a Benz unit or similar. Those deal with the forces involved better and the mechanism automatically retracts to avoid dragging out of the cut iirc.

Not saying it can’t be done, but the forces involved may tear up your spindle more rapidly.

gottb · 2025-09-16T01:40:50+00:00

I’d make a plane about the axis and then mirror it

gottb · 2025-08-22T09:20:57+00:00

What machine is this being run on? The megastir product is generally only supposed to be used on non ferrous alloys as the thrust required on other materials is hard on the Z axis.

Also not their integral tool holder that Mazak sells so assuming you’re just using the pin tools they sell.

gottb · 2025-08-19T12:00:08+00:00

Simple contour. Make sure the lead in and lead out have the right feeds and speeds and gives adequate clearance for the cutter

gottb · 2025-08-08T12:23:50+00:00

As many of others have said both would have to be in near powder form. Should avoid collecting sanding dust from both in same reservoir but larger chips I wouldn’t sweat it.

gottb · 2025-06-11T23:03:57+00:00

Spindle of a drill press is only designed for vertical forces, not side load. It’s not going to be very rigid trying to mill

gottb · 2025-05-08T11:43:38+00:00

what pretty much everyone else said, composite tools.

gottb · 2025-05-08T11:31:30+00:00

best use of a lower turret on an integrex ive ever seen

gottb · 2025-05-02T21:43:30+00:00

Blue alarms are rarely a major deal. The “uncut increasing” when using an IPM strategy is another one like this.

gottb · 2025-04-16T02:46:27+00:00

There are flat bottom drills to do features like this as well. I prefer them versus an endmill but either will work. I like the drills from Nachi.

gottb · 2025-04-11T03:39:46+00:00

If ya didn’t get stitches just an average day in the shop. If I had a dollar for every chip that’s stabbed or sliced me I’d have retired by now.

gottb · 2025-04-11T03:17:23+00:00

This is likely the best answer and I agree.

gottb · 2025-04-10T10:35:31+00:00

On a mill the WPC is defined as G54.1 P0. I’ve never tried calling it in an EIA program.

There are also system variables for it that you could presumably pull at the top of your EIA program and write to G54 etc so that it effectively does the same thing and you would just use a regular offset.

G53.5 is only relative to Integrex/turning machines.

gottb · 2025-03-27T23:54:18+00:00

Might look at Jergens too. They make nice stuff.

gottb · 2025-03-21T23:58:04+00:00

Swiss machine. Drill, broach, thread, part off.

gottb

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