Continuous chips from milling an aluminum block - GIF

[Altair]

Continuous chips from milling an aluminum block.




Previously:

Milling a part with a lollipop end mill - GIF
Sinusoidal milling - GIF
Hot plunge milling - GIF
Two-spindle 5-axis CNC mill - GIF
CNC milling a stainless steel part - GIF

[Toolguy]

That looks like steel to me. Notice the rust on the left end.

[WmRMeyers]

Sure does.

[nova_robotics]

Could be, but the chips look like aluminum to me. Pushing a mill that hard with no coolant will cause steel chips to come off golden, blue or even red hot. Aluminum stays silver in appearance. It's a bit hard to judge scale, but to me that looks like a 1/2" - 3/4" end mill. That depth of cut and that speed would be very high for steel.

Edit: Yeah nevermind I think it's steel.

[Frank S]

Could be, but the chips look like aluminum to me. Pushing a mill that hard with no coolant will cause steel chips to come off golden, blue or even red hot. Aluminum stays silver in appearance. It's a bit hard to judge scale, but to me that looks like a 1/2" - 3/4" end mill. That depth of cut and that speed would be very high for steel.

Edit: Yeah nevermind I think it's steel.

If it is steel then it is probably 12 or 14L

[12L14]

Will try answer as best as I can.

Imagine climb* and slab milling at once, but done with a short VHM endmill(or really stubby HSS one).
You need to sacrifice stepover for that depth of cut, but at the same time it is possible to get much higher Vc(heat isn't concentrating at endmill tip - but is spread more evenly, same goes for wear) and you NEED TO bump up feed drastically(to avoid so called chip thinning - with proper Vc and chip cross section there is no need for coolant, as 90%+ of machining heat goes to swarf).


Good writeup at harwiperformance(Helical over here):

https://www.harveyperformance.com/in...iency-milling/

https://www.basstool.com/pdf/promos/HEM_Guidebook.pdf





and video from Gühring:

Tomorrow I can try to write something about minuses of that milling technique(unfortunately there are many downsides).






*conventional is possible - but I'm avoiding it(except for „springback pass” in some materials).

[nova_robotics]

Hey I own a Chiron! It's awful!