How to Decide Which End Mill to Use in Aluminum | A Quick Beginner's Guide to Milling in a Tormach
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- čas přidán 21. 08. 2024
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I wish he would have covered when NOT to use each. 5 flute will not do well plunging or when there isn't a lot of room for chip evacuation. 1 flute will not leave a good side finish unless you feed really slow. Someone with little experience could come away from this thinking they can all do it all well.
Great statement. I came away thinking that five flute would be best and your comment illustrates how little I know!
Our most challenging cuts are generally a diameter of 10 mm and between 40-50mm deep in POM and Alu so chip evacuation and rigidity are issue. What I would think we should use is a 9.5mm of 3/4" five flute running maximum rpm (6000) on the Haas TM1-P that we are about to buy.
Here it sounds like you just run rpm and speed up with as much stepover as the system can take, but it sounds like that is wrong
well there are so many variables you can cover them all in a video
Good point. He is obviously biased by the fact that his CNC mill is very high speed; my Bridgeport can’t work at that speed, so more to consider.
Yeah, with these guys, it seems to be that they speak highly about the stuff they use on their channel. I'm running a Tormach 1100mx, which can do high speed up to 10k, but some people wouldn't want to use a 1 flute.. I use the 3 flute myself. I need to dial in my feeds and speeds. That's where I suck. I am busting endmills still and it's very concerning to me. I'm new at this, and really need to dial in my speeds and how fast I'm removing material. Calculators don't seem to work all that good for me, because something else is going on with my software.
When machining aluminium, you should aim for the Q value. For pockets i like to use carbide ripper-profiled endmills with coolant, the grooved profile reduces cutting torque while keeping the Q value high. Coolant is really important, and getting the fluid down in the pocket to evacuate chips. That way you ahve a long lasting extremely effective endmill with minimal machine stress and a high q value.
I have great experience with the Paul Horn DSFRA endmills.
Would love to see a video discussing various coatings and when to use certain coatings, what material they should be used on, with or without coolant etc. Been in the job a while but I'm eager to learn new stuff!
Some great advice for beginners, well done. It would also be good to highlight when you should not use each end mill. Using the right machinery for a job is crucial to the quality produced.
Best # of flutes is totally dependent on the cutting application. In high speed machines, making a 2-flute work can be difficult due to cutting harmonics and natural frequencies of machine tools. I have 2 large high speed gantry mills (20k rpm) in my shop and they are very sensitive in this regard. Also, wall thickness calls for a specific flute count such that 2 flutes can maintain contact, which helps stabilize harmonics in thin walls at high aspect ratios. If everything could be machined as quickly as possible with trochoidal type toolpaths, you could probably make a case for a set number of flutes as 'best case' but that simply isn't the quickest way to process everything.
Overall a good intro video though.
this is a really interesting comment, would you care to elaborate on what you have the best luck with on your mill? mine seems to be very similar and I am looking into doing aluminum parts for one of my upcoming projects
Да, тоже интересно
The 3 flute is my go to end mill for a lot of stuff.
I love how "grown up" these comments are! I was trying to listen but all I could think about was Ricky Bobby not knowing what to do with his hands!
I learned sign language today from you
Always enjoy these vids 🙌
I watched this. Then read all the comments. Then went to another video. Then remembered that I did not thumb up this video. Came back to "like". Only Titan gets that dedication from me. lol
In other words, for aluminium use how many flutes as you want as long as it is not 4 flutes. Did I get it right?
nope with alluminum do whatever you can do evacuate the chips, then if you ensure that the more flutes you have the more rigid is your set up so can take more material away (either by increasing speed, good for less rigid machine, or by increasing radial load, for more rigid mills). General speaking if you have to peak a set of tools for aluminum, buy carbide 3 flutes and you are in a sweet spot. Being machining aluminum with those for a while now.
Lesser flutes more chip evacuation : Gummy Material
@@Ale_Lab Thanks. I never worked on aluminum. But did/do on brass (which they say is similar). I use 3 flutes carbide uncoated (shiny white). Similar end mill I use for steel but is coated (black). Is it true that coated is not recommended because it will cause the aluminum to stick to it?
@@danl.4743Machine brass is easier than Alu, you can take more load for the same type of machine. But for sure closer to Alu than steel. For aluminum as I use carbide only and both coated or not. Usually coating helps in the case of aluminum because slippery enough to improve chip evacuation, but I also read what you said somewhere. Personally I make sure to use mistcoolant and feed and speeds to avoid to the alu to get hot. I find way more important to at least blast air and if possible a good mist coolant directly on the cutting edge. That your easier and best recepy for simple setup at the hobby level. You don't need to spend tons on fog buster. Can make good mist cooling with few dollars (you always need a compressor though).
Regarding steel 3 flutes can be used successfully. I prefer to go to 4 flutes for increase core rigidity and you want to bring away all the heat with the chips.
-- better go for dlc coated 3 flute endmill. Best performance
Great tutorial
Thanks for the tips Ricky Bobby!
I run plastics.. and those one flute bits work great.
3 flute is the best option for almost all types of cut.
But not in all types of materials.
could you do an overview on a models for steel and cast iron roughing machines? where there are reliable guides, spindle etc.
Please make a app for your accademy
Yeah an app would be awesome!
@@Absquatulationist Why?
Mobile
I can't remember what brand of CNC machine you are using. Please make your videos longer so that we can make sure more people know what brand of machine you endorse.
Thanks for the knowledge!!! You guys are changing the game!!!
Awesome info, thanks for sharing your knowledge
What finishing pass thickness is usually required for radial and axial passes?
Thanks for this video!👍🇩🇪
very good video..thanks for your time
Hey bud at around 3:15 you say the more flutes the bigger the core. I don't think this is correct based on my knowledge as the more flutes would mean more material removed to create that extra flute. I'm not an expert just using my own logic and experience feel free to correct me if I am wrong! Great video and thank you for the information.
As you add more flutes… each actually gets smaller… because there is more. Less deep also which means it father from center
Why would I use a honed cutting edge as opposed to a ground and polished edge? Could you teach us about coatings? I have a 5 fluters I slot 1*5*d in steal and stainless no problem. Also, what variable helix would you recommend? 35 and 37 is what I generally go with.
two flute was definitely the alluminium milling tool. very hard to break and hard to merge with alluminium when emulsion is absent. The finishing was pretty at provided the run out is zero.
The more flutes you have the stronger the tool but you have a reduced chip clearing ability unless you have a high helix angle.
My experience more flutes the better for finish and especially wear. As long as you can get the chips out and cool. Hangstefers used in a Flood system makes a huge difference. also in theory if you have to spin 7000 rpm with a 2 flute a 4 flute only needs 3500 rpm and is much less chatter prone. I have a 6500 lb acroloc m12 so its heavy but only fairly ridged.
I have tried 3 flutes and the tool wear was poor . 2 futes are really vibration prone and dont last long .
depends on spindle power. if your spindle is too weak for the same tool with more flutes, it will crash.
Very useful Post
If i were to make carburetor floats (example, a tillotson float used on Model A cars) what CNC machine would be best and affordable?
Can you make a video about how to start your own company in the garage? I mean you won't be able to machine a lot of parts with a single cnc mill in your garage. Should I ask smaller company's to produce parts for them or just private people or car shops etc?
If you can't figure that out it's maybe better not to start a company...
Solid
Pay attention to your posture my man! You're still young, plenty of time to fix it. Info was great btw, keep it up!
Whats wrong with his posture?
@@firatyildirim2288 His left shoulder is way higher than his right. This could lead to a lot of problems if he doesn't finde the origin of it.
@@jasonstatement3553 i have the same problem . i am 50% left handed and 50% right handed.
my right shoulder is higher than my left because i always use my left hand to work ( hard work like using knife,bring something ,using axe etc) and i use my right hand to write ,using scissors,draw and all light work.
it is not affect my life.i am 30 years old with 10 year experience in milling machines.
for 10 years, i remember i only sick 2 to 3 days.
So the best end mills for aluminium alloys are slot drills :-)
Three flutes are the best for aluminium alloys, better rigidity and high FPT then two flutes. You also get better cutter engagement, which means there's less of a hammering effect on the work piece allowing for better finishing then two flutes.
@@AeroenginnerJosh Much of this depends on chip evacuation. Plain and simple. You'll notice in the videos where he is using the 3 flute, he is also using flood coolant. That lends to the 3 flute looking so good. If you are only using air, or dry cutting, your mileage with a 3 flute will vary.
@@thetruthyouneedtohear NYC CNC in one video used - i think 5 flutes for finishing and 4 for roughing.
I have no practical experience, and my machinist seems to use snali pace and burn out tools, like ex running a carbide drill at 2-3% of manufactureres spec in alu and burning it out. In our company what we often need to do are 10mm slots (little over 3/8 inch at 1½-2 inch deep) and mostly in Aluminium and POM.
How do you shortlist tools and processes?
@@jenspetersen5865 testing is one way to determine what works best for you. Feeds and speeds play a huge part in the results. For a slot, you want to leave enough remaining stock to cleanup the roughing cut. And finish it with a light stepover.
im gona use thin info on my 3018 pro lmao wish me luck
i have something similar as the 5 flute end mill. the material is a square aluminum tube. it started melting the material after it gets half way of making a 12" opening. what can i change to fix it? any ideas?
I came here from software development I realise I have a lot to learn
So why skip the 4 flute?
One of the flutes of my 3 flute broke, so I ground it away. Now it's a 2 flute!
Have you tried any datron single flute ive heard their really good at removing aluminum
I use them every day, they’re brilliant, however they’re designed for very high RPM ranges, 30-60K for the most part. They work well at 22K though with reduced feeds to compensate. They’re a great option for home machinists too IMO as the price to performance is really solid.
I wish kennametal sold a 1/4 kor5 for aluminum
I dont have a high end cnc but i recently came into a cheap 2hp r8 central machinery t-2119. Whats a good faceing tool for aluminum to use with it?..thanks
Fly cutter
Say one flute endmill is great on composites and aluminum
This video is about a week late...I used a 4 flute vortex cutter full slot and it pulled out and milled the bed last week...
What holders are you using? That's a tool holding issue.
@@zaknefain100 no, I think it's just the forces of the cutter as it was a 20mm cutter designed to do 2mm cuts and I did a full slot with it. I was also going a bit fast feed. I've been told that it will even pull out of a heat shrink. But I was using side lock holder.
@@Mrgnothing1 Ah ok mate. Yeah that adds a lot more context to the discussion. Single set screw on the 20 mm? Still takes a torquey cut to shear one. What was your load meter pregged at? 😁
I run 25 mm in full slot but they're double set-screw at that size. For lower speeds they're adequate, higher speeds and I move to the Nikken & Daishowa milling chucks. They'll still creep in a shrink on really heavy cuts.
@@zaknefain100 @zaknefain100 it was single set screw but if used properly its normally fine as I used it on a different tool path. It was running at 8,000rpm 12,000mmpm and as I was going around the outside of a square plate material that had big radius on the corners and I didnt slow it down enough as it hit at full slot on the corner parts so would have hit it around 5-6000 feed maybe less which I realise now is too quick for a 20mm full slot. And the geometry of the cutter is slightly different from a normal ally cutter it puts more force onto the tool.
We go 2000 ipm with a 749
What is up with the hands movement bro....?
What about 4 flute??
Watch this on mute with "Nobody Speak" playing in the background. The rhythm of his hand gestures lines up oh so sweetly.
Never even mentioned Jethro Tull.
Отлично
I'm not sure I got anything at all out of this video... Said pretty much the same thing for each, then just said one of each to summarize.
Could've been extremely helpful for new guys to cover why NOT to use 4 flutes and when not to use each.
Well, that was shallower than a manufacturers promo flyer...
Wish i could like twice
NO CAP!!!
EZ mode on YT
"boxed" aluminium is not that simple
LoL
for normal aluminium is just high rpm, coolant and normal feed
i repeat: EZ mode
CAN YOU TRANSLATE IT TO RUSSIAN, OR HEBROW?
2:00 Say "Trock Oy Dal"
Is that Yiddish for adaptive clearing?
I think it might be oirish.
This is a terrible video. You need to give some performance comparison on material removal rates. "Great" is not quantifiable and as is a meaningless as calling it sweet or nice.
I am sure that you measure the volume removal rate of a cutter and that is what a viewer would expect with a video title like yours.
Totally agree - you cannot really learn from being told that every aluminum cutter in Kennametals program serves a purpose and when paid they get endorsements.
If you have a machine with much higher HP but less spindle spped - what do you do then - More flutes and deeper cut or does that clog up?
Did you really use 5000 RPM with single flute? That's damn low.
🇺🇸✊
whats the best for 80% arms jig?
5/16” ZrN coated or uncoated 2-3 flute stub endmill(corner radius or square), 2”.
Man, what's up with the new generation of kids talking with there hands like crazy people.
Say it with me people, TRO - CHOI - DAL
It's the word of the last 15+ years. Not always the fastest around the race track though but when you have a hammer... everything starts looking like a nail.
If you put this video on mute and play Lose Yourself by Eminem, it looks like he's rapping.
행님아 한국어 자막 생각 음나?
Si.
Algum brasileiro que trabalhe com usinagem CNC, quero entender a realidade, para trabalhar nos USA. Se alguem puder e quiser me ajudar!
Obrigado!
Some Brazilian who works with CNC machining, I want to understand the reality, to work in the USA. If anyone can and want to help me!
Thanks! @fabinotarouco
Personal Kennametal is good on steel titanium etc on aluminium milling they are far behind their competitors
Try Iscar, or UOP. We are using them in all aluminium alloys and most plastics. Ideal longer neck length for machining taller parts. Very nice and smooth surface finish. We tried other brands , but no one could
match IT!
It’s great that u guys know how to machine. But let’s see if all your knowledge acquired in your shop stands a chance in a big tool and die shops.
Silly comment.
Very nice, but please…stop waving your hands around so much. It’s really distracting.
Poll: How many machinists are voting for Biden??
Every smart one with a soul and functioning brain. Question solved. No poll needed. I'm a tool and die man that fits this.
Super bro
#luckytoolroomskills
Geeeeeezz dude hold yur hands still. 😣