Program a part in CAM and the milling tool is a smooth cylinder cutting through a prismatic part. In reality, it is not a cylinder, it is a bundle of rotating teeth in a flexible toolholder. Every tooth impact causes the tool to deflect and snap back when that tooth exits. The slots measured in figures 2 and 3 were cut with the same endmill in the same toolholder in the same machine cutting at the same depth at the same feed per tooth. The only difference was the spindle speed. In Figure 2, the speed and the tooth impact rate were synchronized.
Getting the speed right is the single most impactful thing you can do in milling. If you are able to do it on a consistent basis, it will slash setup and cycle times. Perishable cutting tools and spindles will last longer. Your costs will drop. It will make the unprofitable, profitable. You will gain more open time and you will win more work to fill it. It will justify investments in new tooling, software and machine tool technology.
1 Comment
4/1/2020 05:58:35 am
As you mentioned, it is important to synchronize the spindle speed and the tooth impact. Is there a way to know what the correct spindle speed is for the tool that you are using? I never thought of the milling tool as a bundle of rotating teeth, this would make sense, because that would be the way it would make the hole.
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