hmmm could be a few things , to high RPM on the spindle , tool not sharp ? best use with a HF spindle is to use a one flute solid carbide , and maybe since i am not sure if the machine is sturdy enough use a smaller cutter (max 4mm or something (loads the machine less, and need higher RPM by default), not sure what you used right now) could be the geometry of the bit is not perfect for alu. my machine makes quite some noise to vibration etc, but the ragged etch i assume has to do with rpm/feedrate/ and quality of the cutter
Thanks so much for your reply. As you will see in my new Part 2 video, I went with more aggressive cuts with this same 6.35mm 2-flute end mill and the top edge is much cleaner, making me more confused! This is the first use of this end mill, so it is as sharp as it will ever be. But, Yes, you are correct, there are so many factors with this work, and it takes a lot of experimentation. With this work, I am moving away from my comfort zone with 3.125mm end mills in Al, to explore the upper range of my machine. Also, I will be buying some 1-flute end mills. Thanks Again!
Sounds like your work is chattering due to not being held firmly enough. Tiny vibrations or movement will create poor edges/finish. With alu, make sure your tool is extremely sharp and check under magnification for any chipwelding. Max two flutes with alu, coolant is an absolute must. If chipwelding has occurred, break off as much as you can, then soak the tool in sodium hydroxide (drain cleaner) to dissolve away anything stuck to the flutes.
Thanks for your comment. In Part 2, I seem to have found a bit of play in the "Y" axis that would contribute to chatter, although accuracy was still good. This is the first use of that end mill, so I trust that it was relatively sharp. I do have 1 end mill that I need to clean, so thank for the cleaning tip!
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hmmm could be a few things , to high RPM on the spindle , tool not sharp ? best use with a HF spindle is to use a one flute solid carbide , and maybe since i am not sure if the machine is sturdy enough use a smaller cutter (max 4mm or something (loads the machine less, and need higher RPM by default), not sure what you used right now) could be the geometry of the bit is not perfect for alu. my machine makes quite some noise to vibration etc, but the ragged etch i assume has to do with rpm/feedrate/ and quality of the cutter
Thanks so much for your reply. As you will see in my new Part 2 video, I went with more aggressive cuts with this same 6.35mm 2-flute end mill and the top edge is much cleaner, making me more confused! This is the first use of this end mill, so it is as sharp as it will ever be. But, Yes, you are correct, there are so many factors with this work, and it takes a lot of experimentation. With this work, I am moving away from my comfort zone with 3.125mm end mills in Al, to explore the upper range of my machine. Also, I will be buying some 1-flute end mills. Thanks Again!
Sounds like your work is chattering due to not being held firmly enough. Tiny vibrations or movement will create poor edges/finish. With alu, make sure your tool is extremely sharp and check under magnification for any chipwelding. Max two flutes with alu, coolant is an absolute must. If chipwelding has occurred, break off as much as you can, then soak the tool in sodium hydroxide (drain cleaner) to dissolve away anything stuck to the flutes.
Thanks for your comment. In Part 2, I seem to have found a bit of play in the "Y" axis that would contribute to chatter, although accuracy was still good. This is the first use of that end mill, so I trust that it was relatively sharp. I do have 1 end mill that I need to clean, so thank for the cleaning tip!