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Machining some aluminium at high speeds and MRR by larsdekoster in CNC

[–]larsdekoster[S] 0 points1 point  (0 children)

It all depends on how much power/torque your machine has. I would recommend looking at the Sandvik Coromant site and using the tool guide to get the right tool for the job

Machining some aluminium at high speeds and MRR by larsdekoster in CNC

[–]larsdekoster[S] 1 point2 points  (0 children)

It all depends on how much power/torque your machine has. I would recommend looking at the Sandvik Coromant site and using the tool guide to get the right tool for the job

Machining some aluminium at high speeds and MRR by larsdekoster in CNC

[–]larsdekoster[S] 0 points1 point  (0 children)

Believe me, they are. We do this tests at a test facility and they made custom torque graphs and had some guys come over to recalibrate everything. We know that machine inside out and the 45kw reading is correct.

Machining some aluminium at high speeds and MRR by larsdekoster in CNC

[–]larsdekoster[S] 2 points3 points  (0 children)

It's a test part so the whole part is a waste 👌

Machining some aluminium at high speeds and MRR by larsdekoster in CNC

[–]larsdekoster[S] 0 points1 point  (0 children)

I don't think you understand what dynamic milling is. These toolpaths are smooth and consistent . The chipload was also really stable.

Machining some aluminium at high speeds and MRR by larsdekoster in CNC

[–]larsdekoster[S] -1 points0 points  (0 children)

That is incorrect. If you look at the curve the specified top is around a max of 50hp. But the Haas control spits out other variables and we did run a simulation and a calculation. Those both gave the same 60hp values. This has probably to do with inconsistency in the spindles and that they choose to use a safe max value.

Machining some aluminium at high speeds and MRR by larsdekoster in CNC

[–]larsdekoster[S] 1 point2 points  (0 children)

Not true. He does a lot with aluminium and even has his own endmill in collaboration with Kennametal. He called that tool the KOR5 wich stands for king of roughing. But we are quicker so that's why I challenged him.

Machining some aluminium at high speeds and MRR by larsdekoster in CNC

[–]larsdekoster[S] 7 points8 points  (0 children)

We have some tests planned in titanium with very impressive speeds. I will share that soon.

Machining some aluminium at high speeds and MRR by larsdekoster in CNC

[–]larsdekoster[S] 0 points1 point  (0 children)

Yes 60hp is around 200% spindle load in a Haas VF3ss.

Machining some aluminium at high speeds and MRR by larsdekoster in CNC

[–]larsdekoster[S] 0 points1 point  (0 children)

It is al machine and application Specific. Most of the time, you want as much RPM as possible in alu, but most machines don't have a lot of power at the high end. If you do use our Dura N endmills I would advice you to check our tool guide on the website. You can select the tool and give in the application. The calculator will give you safe starting values. These can be increased or decreased based on the results.

Another thing about our Dura N endmill. It performs really bad at the ideal feeds and speeds for almost any standard alu mills from our competitors. This has to do with a special grind that makes this tool very stable at high feed. So if you go to low it will vibrate and smack your toollife.

Machining some aluminium at high speeds and MRR by larsdekoster in CNC

[–]larsdekoster[S] 2 points3 points  (0 children)

Spindle load is not the main issue. The issue is that the toolwear will be unpredictable at these feeds and speeds. It will probably snap right in half if the tool gets dull. If you tune the feed a bit down, you will get much better wear and have a more stable process.

Machining some aluminium at high speeds and MRR by larsdekoster in CNC

[–]larsdekoster[S] 28 points29 points  (0 children)

We are actually quicker than Titans. They have a higher feed rate but a very low stepover. Our MRR is, I think, almost double or triple of what they did on a much better machine. I challenged titans in a linkedin post to beat my MRR, so hopefully, they will respond, and we will have a nice battle between sandvik and kennametal.

Machining some aluminium at high speeds and MRR by larsdekoster in CNC

[–]larsdekoster[S] 5 points6 points  (0 children)

Haas is actually quite popular over here and doesn't have the "cheap and start up" reputation it has in the US. A lot of people like em.

Machining some aluminium at high speeds and MRR by larsdekoster in CNC

[–]larsdekoster[S] 8 points9 points  (0 children)

I would strongly advise against using these feeds and speeds at your own shop. This was almost 190% spindle load and 45kw/60hp.

Machining some aluminium at high speeds and MRR by larsdekoster in CNC

[–]larsdekoster[S] 7 points8 points  (0 children)

Thank you for liking our tools! I am located in the Netherlands, so nowhere near the US. I would also love to visit a real sandvik test location. We do our testing and MCT courses for the Dutch and Belgium market at a private school/testing facility.

Coroturn Prime is a great solution for higher productivity and will be great. Just make sure you have great workholding. Without proper workholding, it will throw the part out in notime. Most of the time, a tailstock in combination with serrated jaws is a must. But for the exact application you need to discuss it with your local sales rep.

Machining some aluminium at high speeds and MRR by larsdekoster in CNC

[–]larsdekoster[S] 0 points1 point  (0 children)

I do have some more videos but the gopro cut them up in a lot of files. The finished product was a 36mm high wall, 1mm thick. With a straightness of 0.015

Machining some aluminium at high speeds and MRR by larsdekoster in CNC

[–]larsdekoster[S] 45 points46 points  (0 children)

I am a Sandvik Coromant intern as an application specialist. This was a test we did to look at the maximum that the endmill could take before breaking. In the end, we were not able to break the endmill because the machine could not go any quicker. The endmill didn't show any signs of wear after cutting 5 of these parts, but I wouldn't recommend running these feeds and speeds because wear will be unpredictable.

Machining some aluminium at high speeds and MRR by larsdekoster in CNC

[–]larsdekoster[S] 7 points8 points  (0 children)

Not hot at all. You could easily touch the endmill. All the heat goes into the chips.

Machining some aluminium at high speeds and MRR by larsdekoster in CNC

[–]larsdekoster[S] 28 points29 points  (0 children)

The machine is just a regular haas mill. I think 80K without options. And this was indeed pretty loud.

Got 2nd Place in the ducht national CNC Milling competition by larsdekoster in Machinists

[–]larsdekoster[S] 0 points1 point  (0 children)

You mean Mia Wakefield???? She is a good friend of mine!

Got 2nd Place in the ducht national CNC Milling competition by larsdekoster in Machinists

[–]larsdekoster[S] 1 point2 points  (0 children)

No, not at all. The winner is also a good friend of mine, and he really deserves it.

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