Hot plunge milling - GIF

[Altair]

Hot plunge milling.




Previously:

Ceramic end mill roughing Inconel - GIF
Machining Inconel with ceramic grooving tool - GIF
CNC machining Inconel - GIF
Glowing hot hard turning - GIF

[Toolmaker51]

Heck; why no description of material, cutter choice, RPM, FPM.....? Carbide cutter, probably AITiN (Aluminum Titanium Nitride), guessing 1/2" ~ 5/8" diameter, 4 flute, ~1/8" corner radius The real issue in plunge cutting is chip evacuation. Setup in GIF runs well enough at depth, but they're awful close to a jam ramping down at the beginning. Cutting raw solid material is one thing; chips blocking fresher chips one of leading causes in tool breakage.
My guess is insufficient high pressure narrow air stream across the cutter, into the helix out of the ramp (air from left side).
https://www.hannibalcarbide.com/tech...m-coatings.php
Yeah, a home state company. 'We' still make things here.

[WmRMeyers]

Do not try this at home, kids...

Not with any machine I own anyway!

Bill

[Toolmaker51]

Plunge at least partially counteracts a conventional lead screw tendency to pull into the back lash, with a little drag on gib clamp; where climb profiling usually refuse cooperation. When unavoidable a 'rougher' aka 'corn cob' withstand climb better.
Haven't tried much plunging steel with one, but it ran aluminum terrific, at 1.5 diameter depth. The GIF could be close to 3x, just intermittent squeaking.
Squeaks are cue that cutting isn't up to snuff, lathe, mill, sawing, even a hand file; have to bump rates to find sweet spot. Could be to increase or reduce. Best justification for variable rate control.

[CharlesWaugh]

More accurately: Ramp Entry - Plunge is staright down. As in drill press.
Most endmills are not good at plunging due to zero rim speed at the center (which is why drills are relief-ground to the center-point (hard to do effectively an a flat-face endmill).
Note how the plunge roughing done here is stepping in using just the perimeter of the tool:

(jump to 1:54 to hear him explain plunge roughing)
And, plunge is kinda hard on spindles, who like side loads better'n axial loads.

[Elizabeth Greene]

In the top video watch the spindle around the 15 second mark in the slotting operation. It might be a trick of the light, but it looks like deflected notably. Perhaps it was pulling the toolholder?

I'm sure they did some hard math on this about cycle time vs. tool wear. I don't have access to a machine that couldn't do it, so I'd have to use a much slower adaptive tool path that would take eons.

[mccwho]

That is one powerful mill head. You can hear it trying to chatter.

[Bhop]

In the top video watch the spindle around the 15 second mark in the slotting operation. It might be a trick of the light, but it looks like deflected notably. Perhaps it was pulling the toolholder?

I'm sure they did some hard math on this about cycle time vs. tool wear. I don't have access to a machine that couldn't do it, so I'd have to use a much slower adaptive tool path that would take eons.

No tricks with the lights that thing definitely starts to wiggle its hips. Glad someone else saw it too