Pushing CNC Machining Past Failure | 800 IPM | Kennametal
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- เผยแพร่เมื่อ 29 พ.ย. 2017
- Titan Gilroy tests out the Kennametal Stellram Shell Mill. CNC Machining.
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#kennametal #stellram #machining - วิทยาศาสตร์และเทคโนโลยี
(Spindle talking to Aluminium): *Bite the vice, i'm going in dry*
Lmao
Lol
😂😂😂😂....how long to come up with this gold?
Lmao, top comment.
🤣🤣🤣🤣🤣
Haas Spindle: “Why do you hate me?”
"Because you're a HAAS."
nothing personal just business
Haas deserves just as much hate as their customers receive from them.
This coukd be a new sport discipline.
CNC Drag Racing
Cool Right:-)
Haha nice one :D Haas vs DMG :P
😂
Lmfao!
that actually sounds like a cool idea, people try to make their machines the fastest and compete for a prize. kinda like those chainsaw competitions where they gotta cut through a log as fast as they can 3 times or whatever, just with metal and big azz cnc machines. ok the guy with the sawzall can come too
It's not about how fast you mow. It's how well you mow fast.
Gotta Push it... Relax it... then Kiss It.
SpaceX doesn’t complain
@@TITANSofCNC just looking out for you here, you might want to delete this . confidentiality agreements and what not.
@@MrEtronic It's a 2 year old comment. If it was going to be an issue, it's a bit late now.
Elisha Robin you’re a moron
@@ThumbDr real original
IPM looks cool. When it comes to roughing, it's MRR (Material Removal Rate) which counts.
The customer pays for the finish cut. You make money on the roughing cut!
That's a great point!
Exactly this. You passed the MRR of the 800 IPM (inches per minute) cut with 1.5 in. WOC (width of cut) all the way back at 450 IPM with the 2.7 in. WOC.
Ya make your time roughing, ya take your time finishing:)
Maybe true but power milling is hard on your tools and your machine. I can turn an endmill into a ball mill and still finish the job before I’m even aware of it with high speed machining. My parts come out flatter and my walls are straight within tenths. Aaaaaannd I don’t have to tighten the crap out of my delicate part. Power milling has proven to be faster for sure but when that tool breaks, your holder is damaged and that part is scrapped hsm will have put more money in your pocket from said customer. Unless you have a spare tool in the carriage and the part hasn’t moved and verified it hasn’t. A continuously running hsm program will leave you behind and give you over 3 times the tool life.
A high speed machining rough cut is practically good enough to pass as a finish cut. Your finish cuts should be even faster because of chip thinning
I use a different approach. I set up my machines to run as many parts as possible. I bought a brand new, gorgeous VF5XT last year and I fill the 60 x 26 travel with parts. this gives me a 9 hour run time with tool reliability. I can run the machine during the day and then get another run in at night. Maybe I could push it harder but as its lights out machining with nobody at the shop I'm happy with a program that is reliable and doesn't break tools.. ever.
Thats a good approach to alot of small parts, but big parts or ones where you need 4 or 5 ops for completion, it isnt doable.
I'm in business to make money, not the tool supplier money. ( I tell my guys that all the time )
Cool approach, will remember for when I'm finished building my wooden diy cnc
Here I am 2 weeks into Precision Machining classes and I'm reading OP's comment like "Wasn't one of the first things they said in the safety course and safety tests, to not ever leave a CNC running unattended, and to keep an eye on the entire process"? Lol
Hear that..thats how we do it too
Eat
Easy to push it on aluminium. Show me the boundaries on 300 or 400 series steel. I'm curious.
300 and 400 series needs some gentle loving by the tool😆😆😆😆. We all know what happens when you try to push the envelope with 300 and 400 series. Tool life goes haywire!!!!.
I wanna see it on carbide
Let's see them cut inconel
@@Chevydevil incolnel good, but better yet is mars
See it on some D2
Gotta say i was amazed at the surface finish at 700 ipm without coolant. Absolutely amazing.
Hey , just a thought , If you back off radial another 1.5" , you could go a bazillion ipm.
Very true, And that would prove, ipm isn't always the answer.
Just what I though.
Eiserntors Phantom of the Opera
METAL REMOVAL RATE. volume over time.
Interesting, never once that I have seen does he mention CIH...going fast looks cool. King of roughing ..wonder what he finishes at. Or what is acceptable for tolerance variance.
The cost study on new inserts, tooling, and machine wear vs. 1 minute saved on cycle time. Marathon vs the sprint.
We save way more than 1 min and Crush the competition when it comes to bidding. Rough Hard and then Kiss it... for the Win.
@@TITANSofCNC
We rough hard too. Inserts last through alot more parts. Interesting how sometimes you're at 60 hrs for the week, YOU (well me anyways) DONT WANT TO WORK SATURDAY, double the feed rates, get it done, and see ya'all Monday! 😉👍
Lol and then there's me who has to run the same part 24/6 for 5 years so this kind of nonsense is idiotic unless I want phone calls at 2 am from a production guy who only knows how to put another tool in and blow it up too. In mass production cycle time is even more important than for the jobshop guys, every single second is counted. Including those you spend flipping the inserts every 3 cuts.
@@e23561 they completely missed the point I made about machine wear. Trying to normalize apparent machine abuse is a desperate grab at youtube views. @e23561, good point about downtime as well
@@rodidy Is it your experience that tools and machine has substantially more wear PER PART if you run fast vs slow?
I would assume that on the spindle ex - it would be a very hard, expensive and time consuming study to make.
It seems like a lot of parts are unnessacarily expensive due to slow processes, and as with anything backing 10% off the max. is probably a lot more durable than backing 2% off, but the difference between 50% and 90% is likely miniscule in wear.
I just found this channel...
This is every $10hr, employees wet dream 😅 tear shit up
"Today we are going to ram our beautiful F350 into a concrete well just to see how much these trucks can take..."
i mean thats whistlin diesels entire channel
When your chips are thicker than depth of cut...Lol
For real
I'm still pretty much a newb, so I'm curious why the coolant wasn't turned on for the original 2.7" step over.
I know my machine pretty well and wanted to run it for as long as possible with no coolant... simply because I wanted to have a clear view on camera of the cutter actually cutting. Just for Camera - Not recommended.
I thought that might be the reason. It's one of the reasons I prefer mist on mine.......but I only have 2hp.....so I'm on a completely different playing fields. lol Thanks for the response!! Thank you for everything you are sharing with the rest of us!
Mike
I thought that might be the reason. It's one of the reasons I prefer mist on mine.......but I only have 2hp.....so I'm on a completely different playing fields. lol Thanks for the response!! Thank you for everything you are sharing with the rest of us!
Mike
Richie Bhoy yeah but they'd shame themselves by making dumb remarks like that....
I run a HASS 5 at work with steel parts and just use coolant when drilling. We just use compressed air when milling. The boss says that the tips we use are designed to be run dry so that`s what we have to do. Don`t really know if it`s right as the place is a bit weird lol.
Thanks for the video. Am so glad I have finished work, I had to work on VF3 and VF6,since 1992. plus old M/C in which I prefer . Have fun, I used to program and operate, they always wanted more..UK England,
You didn't show the surface finish after each pass? Also, how well did the inserts hold up under the extreme load?
very nice tutorials,
i watch almost all of them
Can yu please tell me whats the best insert i can get to machine cast iron
RA VALUE SHOULD BE LESS THEN 3.2
So how was the cut on the 500, 600, 700, fpm no coolant runs? As a non-machinist, I'm curious to see how much snipe or chatter there was on the (Y?) axis end of the material. I assume the Z was rough as well. (X?) went through on all but the last pass, so there was nothing to see there. (Not sure if the X was the plate motion, or if the Y was, but I'm assuming X based on the load factor on the screen)
You da man! That is some scary stuff you just did and pulled it off nicely. Since I work with mostly plastic, aluminum, and stainless steel to me this is very impressive. I hope one day I can make it to just half way to what you know about cutting stuff. Keep up the great work as you are an inspiration to a lot of us just starting in on machining.
Nice
More positive inserts play a massive difference in spindle load also. Can often increase cutting date this way and also reduce load.
What about the finished surface at this amazing parameter? Have you documented it?
That was awesome! Would love to see a comparison of the finishes for each cut too.
I want to see 800 in inconel.
Me too... Sparks
Cermet inserts on a lathe. No problem. Makes up for a nice set of firecrackers.
Wow a feedrate
Just go .100 deep, then back off about .101
I always wanted somebody to sneak into WESTEC with some Inconel and swap the leadloy out for it in somebody's demo.
If you never break a tool, you'll never know how fast you can go
Smyth Diana True. We have to err on the side of caution. I cant go to my boss with a destroyed $800 facemill. I just cant. This was awesome because it is something we all want to try.
Smyth Diana that ridiculous . It’s alll science . Understand sfm chip load materials and tools
@bobwatters Absolutely a good machinist instinctively knows when they have the feed and speed right, this takes years of experience, you can talk all the formulas you like but my ear with 35 years in the trade knows best, in any case the maths isn't always get it right in practice.
I hope you don't make love like that Smyth ;)
@bobwatters Indeed, and that does not qualify them as machinists, manual machines are still needed to back up CNC and if you don't have the skill you are in trouble.
Awesome video. Just wanted to know if you changed the inserts for every pass?
Thank you for all your effort to teach. Please let me understand better about the "sweet spot point" This point is between 80'to 100% of spindel load?
Your an epic man and amazing .... inspiring and brave .... nice demo and its a great tuturial who understood what were you doing ....
Man that was smoking, a good job good results and good to see Stuart predicted correctly the outcome at them settings :)
Pretty cool test. 162 in³/min @ 600ipm is more than I expected it would do. Those Stellram cutters are very nice. Do you know how low the rpms dropped on that 600ipm pass?
When can we expect a test in steel? :)
I am going to start testing a lot of tools in different materials and machines. This will be a regular feature : Tools of Domination.
Yes we want to see you break shit!!
I loved this! As an apprentice machinist this guy can show me da way... haha awesome keep up the CNC videos! coming from washington state! The future must hold more machinists!! lets go!
How much effect do you have in your spindle? Sometimes we just hit machine limit before tool limit.
Are you really gaining ground though? Pushing to 800 is great, but if you're reducing your radial to do it, is it worth it? Especially considering wear on the machine?
Great video though, thanks.
They real machinists calculate their Material Removal Rate vs their chip load.
ive got to be the biggest viewer i come back and watch this often .
I was checking out that spindle speed I fig you had them RPMS up there lol. Good video
Have to love the variables, from a parametric programmer👽
Do your machines come with body armor for the operators ?
We just got the same ngc control in (2018 haas vf5xt). I noticed your chip load you see on the screen is reading correctly as a 4 flute cutter. So far I just programmed tool length and dia of tool . Looks like there is more for me to add (# of flutes)
Hello.What is Your Best Insert for Monell Welding Interroupted Cut For a Lathe ?
THANKS.
at collage I try to push the haas mini mill to it limit, it got a 6000rpm 5.6kw spindle(7.5hp) I then got it running at 7500 mm/m feedrate which is about 300ipm, I then chickhen out as the spindel is reach over 8.9kw(8.9)
Awesome video, You're the man. Is Kennametal your brand of choice for indexable cutters? I'm sure you've tried a variety of brands and know your stuff so I'm just curious. I'm in the process of modernizing my machine shop and I am currently focusing on tooling. Keep it up!
i started my cnc-carreer about 1,5 years ago with lathe turning... my colleauges called me crazy for roughing aluminum with stainless-steel-inserts at doc 5mm f .5mm v 500m/min :D
i just started introducing high power inserts for roughing, pushing productivity by +300% - +800% depending on material and possibility to get good grip ;-)
love your show,
PeacE :D
Nice nob there , in my experience the sweet spot is a resonating sound that feels like music to the ears. When you hear it you automatically get to know that neither the spindle nor the tool is bearing any abuse. I work in millimetres and using 45 kw spindles , 22000 RPM a feedrate of 7000 - 8000 mm/min , and depth of cut 4-5 mm it feels like and orchestra . With smaller tools 3mm depth of cut is better and safer. Whats your spindle power and torque ?
wow, im surprised the surface finish was still very good at that high feed rate, great vid guys.
Why so many dislikes?? These dudes are out there breaking expensive machinery on purpose! Here's my like and my subscription!
Because you can literally figure this out doing the math with a catalogue without breaking anything
Hey Titan what would happen if you made a cutter body or bought one that can hold 5 or even 6 inserts I bet you could even go faster bring down your chip load by adding inserts....
if you get a holder that has 5 or even 6 inserts you could actually run the spindle ccw. Or atleast in theory...
The inserts are still facing the same way, how could you go ccw?
You'd bust them off
ccw?
Ccw counterclockwise... running it backwards
Man,turn the quill on.
What a crack up.
Great demo thanks.😁
A couple questions, what grade was the aluminum, and did you step up the spindle speed when every increase of feed rate, or did you run the spindle speed the same rpm for every test?
6061 is what he said at the end.
Put a larger diameter cutter in an go at less than 50% width of cut, that way the cutter is always climb milling and reducing the force.
Makes no sense if you want to go fast... larger diameter = slower
I want one of your titans of cncs T-shirt’s! I enjoy watching the videos you guys post!
You're positive the sudden large load and smoke isn't from the tool rubbing behind/after each insert?
Are you keeping your chip load constant every pass?
The Fadal I was running yesterday cant even rapid at 800 IPM more like 700 ipm rapid at most. This is crazy stuff.
The coolant made the most difference I'm sure.
Adding the coolant,I bet, made a difference. I wonder what would've happened if you increased the spindle speed?
Titan, bearing into the spindle going to be affected? This was interesting test!!
THANK YOU KENNAMETAL
but I could make the machine work faster by increasing the depth of cut so what do I do make it machine slower with a deeper cut or make the machine work faster? or some combination of the 2?
I wonder how much of a difference it would have made if you were conventional milling, rather than climb milling, on the original 2.7" step over. When you were on the 600 & 700 passes, it had that big wall that may have messed with chip evacuation. (P.S. I am NOT a machinist. So if that's an absolutely stupid observation and query, forgive me.)
Also, I would like to see a video of milling with & without coolant. For example, if you did the *exact* same cuts with coolant and without coolant. Maybe with a parametric graph with the spindle load % & kw, HP, and surface footage. So we could see whether or not the coolant makes an appreciable difference, or any statistically significant difference at all.
Maybe even one comparing MQL, mist, HP vs LP flood coolant, WD-40, brushed on cutting style lube like the old school guys use on the manual machines, etc.
Nice video and I learnt a thing or two.
The only thing I don't understand is why the emphasis is put on feed rate while there are more variables contributing to material removal.
Making money with a machine means removing volume as quickly as possible, which would mean cubic inches per minute.
The 600ipm pass at a 2.7" stepover was 126 cubic inches per minute
The 800ipm pass at a 1.5" stepover was 120 cubic inches per minute BUT with reduced spindle load
What I would suggest in search for a metal-hogging recipe is to be at full depth of cut, keep the maximum feed rate and play with the stepover. The reason being, you're paying for big inserts but only use .1 inch of the tip.
Any thoughts?
2.7 was definitely a higher HP also... My point was not to bury the tool but just to show everyone the tool could handle a lot... so don't be scared to experiment. My normal feed as seen the the spark plug video is 300-500IPM at Z-.2 which gives me a nice MRR.
𝖘 𝖍 𝖎 𝖗 𝖔 you're right a more complete doc would use the insert more efficiently. Though generally a tool of that size your probably using more for facing style cuts, not so much mass MMR, there's more suitable tools for that
I cut mild steel every day with sandvick r.390 inserts. One thing I've found to save the cutters and inserts is to either be above the screw or below it. Having the cutting pressure concentrated at the thinnest part of the insert leads to inserts breaking. Best strategy is at 1/3 of insert or 2/3. I cut at 40 ipm with 1 inch sandvick and .5 depth of cut using air through tool on my HAAS VF5 XT. Btw, I've been machining since 1980 and the HAAS is the best machine I've ever used. Yes, I've owned Makino, Matsuura etc. HAAS wipes the floor with them.
You should try some DMG, Mori Seiki or Hermle Machines. Those wipe the floor with anything else you know.
"HAAS is the best machine I've ever used" haha
That's dope I wish I could learn from you 👍
Interesting to see this demo on alloy. I would like to see the result if you had tried to do fast speed (ipm) before you had reduced the height with previous cuts. More leverage on part, that would be interesting! Cheers from John, Australia.
20.3 metres a minute is certainly travelling. What RPM were you running? What grade aluminium were you using? Material has a big bearing.
Insert geometry also has an influence.
All machining is a lot of trade offs between speed, tool use, wear and number of operations in a job.
The rapid traverse rates and speed of tool change also can have a bearing in time taken.
Would be interested in seeing this performed on steel tho.
Sir , can you please suggest me the best but economical 100mm Dia milling cutter with insert specifications for Aluminium alloy having 10% of silicon...I'm waiting for your reply, thank you
Currently I'm using SDHT04
The video show you fast the thing cut but doesn't show you tool life comparision, the over all money ratio to profit at the end.
You must not have watched the end. I simply was showing the the tool can outlast the machine so don’t be scared and then backed it off and said 400 was the sweet spot
We run at 400 all the time and never have issues at all...
Could you try this same experiment with nitrogen cooling the cutter?
This kind of experimentation is fun when you have the time to play like that. I"m curious, when you hit 600 IPM, what was the chip load per tooth?
Assuming a 12k spindle and 5 inserts the chip load was . 01 per insert per rev
Hahahaha love it. Look at the chips, this is realy to much.
Greeting from the Netherlands
Titan what do you think about Walter mills?
Cutting your MRR by 25% to get to 800ipm, thats not epic manufacturing, thats an epic fail.
Christian Forthofer i worked with a programmer like this. Run crazy speeds, pop the program in, and walk away. Then get pissed we you bitched that you were changing tools every 15 min. $100 in turning inserts by the end of the night with only 0% increase in production because of all the downtime rebuilding tools that failed early.
LOL technically a little MORE silly video showing how to do it the wrong way and HURT production AND Tool life at the same time
@@pharaun159 LOL I had a "programmer" come in on a weekend with me, turns out we were programming the same part. His took 2.5hrs and used a 6" long R390 to do most of the roughing, 45 minutes on one tool. You actually had to stop in process, change inserts, and restart from the beginning of the tool.
My whole program took 45min and you could actually run it without breaking a tool.
He was one of those guys that graduated the machinist course and thought he was a programmer worth $26/hr.
Yeah...I've worked for an owner like this..crank the piss out of it and in 304 or 316 ss, make it through one or two like a hero and walk away for u to inevitably have a crash later...not his fingernails getting chewed....prick
by my crude calculations 2.7 x .1 x 444 ipm = 120cu in per min. 1.5 x .1 x 800 = 120cu in per min. also I would say that the tool can handle it just fine, the machine taps out.
And Hardness materials are different 😉 ..moreover you're amazing ..whereas you're risking a lot in this trial ... You're the best 👍
amazing!! I thought you were going to burn it up the first 700 run
i assume you used the same side of the inserts for all the tests? there was probably build up on the inserts once you got to the high IPM
Amazing, so exciting
Love it
For me usually is the workholding that limits the speeds. I can dial in the numbers even larger MRR than that in video but either there's too little material to hold on or poor selection of vises at the moment. Eitherway it costs money better known as opportunity cost. Proper tools always pays off in time and only thing that you can't replace is time so that will always be the most expensive thing in any shop.
Cool vid. but need to know rated power of spindle and chipload per flute as well as chipload per revolution! how many revolutions per min? gotta know stuff but cool vid either way!
It's amazing to see the limits of a machine , but in real life application , this is too scary. Over 400 it really gets out of hand , if something breaks , even "only" 200 brings your hearth rate up :D .
Now i wanna see some super high feed turning even if it's just aluminium . (parameters like .1 radial depth , feed .05"/rev , and cutting speed about 6000SFM)
You must not have watched it til the end...
i did , but that is just too much for the machine . so what about pushing turning to the limit ?
Kiss peter that is the reason the shop I work at loses money, one guy runs and saves aggressive money making programs the next guy "ooo that's too much" and drops feeds and speeds by 50% and burns up tooling
I would've liked to see some chip analysis on this, just to see what kinda chips are breaking across the board at the different feeds.
I could almost smell the metal at 600, haha... I wish I was there to see it live
Hey can someone direct me to a place where I can buy aluminum like that? I’m not a machinist and I don’t have access to tooling equipment (sadly), but I DO need aluminum for metal casting, and seeing that much aluminum being shredded to bits is slightly infuriating tbh
have you tried googling "metal distributors" ? or if you're looking for a low volume of metal and want to make it simple check out mcmaster carr ( mcmaster.com )
I was under the impression that you did not want to enter the cut right at half the cutter diameter, because it is the weakest part of the cut for the insert. For example enter the cut at 1.6" or 1.4" I could be wrong
Very nice video, thanks for uploading
I want Type3 Software, do u have it?
That is the best thing I've seen in a long time it probably would have went through if it had new inserts
B.e.a.utiful. I just bought a Stellram for my shop, they put me in charge of CNC machining, programming, tooling. I don’t know if that’s a good thing or a bad thing. The old guys love their 20-30ipm. I showed them the Stellram today took it up to 600ipm today.
I find the finish so good on the deep cuts
Excellent....been looking for a quality Toe Nail clipper/ file.
Was that a Pittsburg Dead blow hammer?!
Looks like it but so what it works.
How much does that cutting head cost? And did you ruin it for future work?
Is this aluminum or aluminium? Can't tell.
What 5 axis rotary model is that?
Titans dope a.f!! Titan let me go on a shop tour!!!???
lol we are using the GARANT feedking and we can mill at vc=1500m/min F=1,11mm (per tooth).... is it faster? AlCuMgPb
Titan, while finding the sweet spot on any machine is the key to productivity I have this feeling that you wont be happy and you want to make a machine that can actually do 1000 ipm no matter what material you put in its vise !!
What is the best software or application for calculating speeds and feeds for cnc machining?
NOVO from Kennemetal is Great
@@TITANSofCNC Thanks Titan.........Amazing Response Time. All the best to you in 2019!
400 ipm looked like the sweet spot
OOOH WHAT A WORLD.....It was when tape readers and auto-chuckers ruled the world..!!..I toured the Hardinge plant in Elmira in 83' when my company bought their first Super Slant...Kennametal gave the Spectra Physics fab shop some of their first production tooling to try out on the floor..It was good back then, but now OMG..
Mgyver D but a HLVH is still one of the best machines ever made, aside from the 10EE.
Great video most enjoyable for sure'
that was pretty good that's not on common though here in my shop I run milltronics and Hoss's to VF ones and be able to use that I cut a 250 all day long on the aluminum never have an issue
What does "stepping in at -2.700 radial" mean? What does the "radial" parameter mean?
Just that the tool is 3.0” and 2.7 is engaged in material cutting.