Double the maximum RPM on the Machine Details page over its actual maximum and generate a Dashboard. If there is a stable range above the actual maximum RPM then you may be able to bring that lobe into play by increasing the tool's stick-out or using a longer tool. Extend the tool, re-tap and genera...
In most cases, if we stabilize the milling tool, workholding vibration issues go away. If there is still chatter present at a stable speed according to the Dashboard, first use the Harmonizer software to measure the part vibration and calculate a new speed. Alternatively, tap test the tool and gene...
If you have a thin wall part that is vibrating even after tap-testing the tool, you can tap test the part itself. Use the same settings as the tool. Tap the workpiece before machining (thick state) and in its finished state (thin). Create a Dashboard for each and use VirtualRunoff. Find a stable spe...
Tap-Test "Monument Tool" (e.g. their most popular tool) to baseline the spindle. Use Dashboard to program part. Periodically tap-test the same tool. If the resulting Dashboard requires reductions in the program speed or cutting depths, make a cost per cubic inch calculation vs. spindle repair cost t...
First, calculate the feed rate in Inches Per Minute (IPM) for a straight tool path.For an internal hole use this formula:Optimized Feed (IPT) = (Major Diameter - Cutter Diameter) / (Major Diameter x IPM)For an external path, use this formula:Optimized Feed (IPT) = (Major Diameter + Cutter Diameter) ...
This diagram describes the physics behind what is called a cantilever beam. A cantilever is fixed on one end and free on the other. An endmill is a cantilever. The symbol δ is the deflection of a beam from a force (F) applied. The equation below the graph says the deflection (δ) is in proportion (∝)...
Yes, make sure the same milling tool assembly is in each spindle, the same model toolholder, cutting tool and the same stick-out. Tap-test each tool in its spindle and generate dashboards. Use VirtualRunoff and find a stable speed, depth and width of cut that is common to all of the tools and spindl...
When it comes to high feed milling cutters, trochoidal milling and radial chipping thinning you have to be careful of "calculated" metal removal rates. They use very high feed rates (IPM) to achieve high metal removal rates despite their low axial or radial depths of cut. In the case of circular tro...
Here we are milling a flat on a round part. Set the axial depth of cut on the Dashboard to the highest point on the round. This will ensure stability through the entire cut.If you are milling an inside pocket and will be making right hand turns in the corners, set the radial width of cut to a full s...
If you are making an L-shaped cut (wall and floor) with light width and depth cuts, you will need to adjust the Dashboard output to account for the air cutting.Use the attached spreadsheet to make the necessary calculations and adjustments to the Dashboard.
When milling an angle such as this, your depth of cut setting on the Dashboard may show stable green zones that will chatter. In this instance, increase the depth of cut (to be safe double it) and use the stable zone recommendations.
For endmills from 3/16" or 5mm to 3/8" or 10mm, you can use the optional mini-hammer and accelerometer.The Mini-Kit consists of the following: USB Y-connector (use if you do not have enough USB ports) 086D80 Mini Hammer and Cable 352C23 Mini-Accelerometer USB Drive with Sensor Database for Mini-Kit ...
Let's explain why damping (that is the correct term, "dampening" means to make wet) works for boring bars and not so much for milling toolholders. The green and red charts represent the different toolholder responses to being hit with a hammer one time with the same force. They both deflect, rebound...
We are carrying some of these new tool path strategies a little far. Last week I was asked to tap test a 3/8" 3 flute endmill with a 4" length of cut. They wanted to cut at full depth in aluminum. That is 10.66X the diameter! It was like measuring a wet noodle. There were no stable lobes at any spee...
The impact of the hammer is at an angle and not perpendicular from the accelerometer face.The hammer impact is too high axially on the endmill in relation to the accelerometer location The impact of is not opposite and perpendicular to the accelerometer face.If the hammer tip is not aligned an overl...
You can use the accelerometer on the same side as the hammer.1. Click Setup2. Click Measure Tab3. Click on both Response Direction buttons so they show minus "-". Note the change to the image below.Be sure to return both Response Directions to "+" after finished with this tool.
Use only if instructed to do so. Save the three files below to your desktop. Open MillMax and click on the Open Dashboard Folder button. Drag the three files into that folder, replacing the existing files.
Use the same machine, toolholder, tool and material settings as you did for tapping the cutter.1. Click Setup2. Click MEASURE tab the click on the X Direction Response Direction box changing it from and "x" to a "-"3. You will see the graphic change with the accelerometer on the same side as the ham...
Different manufacturers refer to this differently. Kennametal calls this 0 (zero) degree lead. Others refer to this as a 90 degree lead. For the purposes of MillMax, use 0 as the entry for lead angle for this type of cutter and for solid endmills in the Tool Details page.