Can somebody help me, on how to calculate the right feedrate in mm pr. min?
I know it is only a guide number.
I have a 2 flute end mill at 3 mm.
I run my router at 15000 rpm
Cutting depth is 0.1mm
I`m cutting hard alumimium.
My max feedrate is 1000 mm/min.
The table i use for chip load says 0.05 for hard aluminium.
Router is 2 HP, 3500 - 30000 rpm
From the sound of the cutting, the ideal feedrate is around 300 mm/min. But my calculations says 1500 mm/min.
i have any videos cutting 1,5mm aluminium sheet with 1 flute at 18000rpm with 600mm/minute… for 2 flutes i think about 10000 rpm and 500mm/min feedrate but the most important is the cooler of the tool i think oil or some oil spray or pulverized water with a bit of soap… deep about 1,5mm to cut
Giving your tried speed of 15000 @ 300 compared to 10000 @ 500, then your ears was quite right in fact. Yours and the calculated would result in about the same chipload. But the little higher feedrate and lower RPM will probably reduce tool wear though.
Usually when working aluminum you would use spirit as tool grease. Just spraying it by hand. This is because aluminum and spirit work well together just like iron and oil.
Does the type of end mill matter? Belive i’ve seen some end mills that are made for cutting alu at high speed and no coolant (coolant actually make them work worse) … ?
@Michael_Jacobsen As far as I know, coolant is used to the chips would not stick to the bit. Otherwise you will end up with a chunk of material on your bit. But since you’ve seen, can you post it? I’m interested what kind of bits they are.
the N=1000Vc/Pi/D is not an empiric formula : it is the required formula.
F = N x Z x Zf is too.
Pb : it doesn’t give the required power for the spindle. Such a power formula exists : it requires to calculate the Force of the spindle on the material.
If you reduce speed because spindle cannot turn theses speeds, you must adjust the F formula according to your real spindle speed.
Be aware that there are 2 kind of cutting techniques : classic with low speed and high forces (high power required) and high speeds with low forces. Spindle are part of this last one. The 2 techniques don’t overlap. So you should be aware that you need to run at high speeds (>7000rpm) with your spindle.
Good luck