09-15-2016, 07:43 PM
Ed,
Next time you try a cut, do put up any chip deflectors you have and prepare to make blue chips.
I don't recall which grade of insert you got but very conservatively any of them I would have recommended (WKP35S or WSP45) can run 1018 CRS at 300 to over 1100 surface feet per minute. Assuming we stay low at 300sfm, that would be 572 rpm. for the 2" cutter. Now a feed rate. At 0.005" per tooth x 4 inserts x 572 = 11.44 inches per minute.
If you had a power feed, then it would be a conservative ballpark tolerance to set it at 10 inches per minute. Since you don't have a power feed (yet), consider the piece is 4" long, so at 10" per minute it would be 4 ÷ 10 = 0.4 minutes or about 24 seconds to make the cut. Make a practice pass above the part to get an idea but just the long side of one rotation of the handle per second.
You'll be shocked at how easy it cuts and how nice the finish comes out.
Oh yeah, try to get a 0.030" to 0.080" depth per pass. Instead of straddling the 2" mill centered on the width of the workpiece, have it cutting off-center by shifting the cutter to have little overhang on the exit side of the cut but no less than center of the cutter in line with the front edge of the block. You don't actually want to be climb milling in the pure sense, but try to avoid straight-up conventional milling with that cutter.
Next time you try a cut, do put up any chip deflectors you have and prepare to make blue chips.
I don't recall which grade of insert you got but very conservatively any of them I would have recommended (WKP35S or WSP45) can run 1018 CRS at 300 to over 1100 surface feet per minute. Assuming we stay low at 300sfm, that would be 572 rpm. for the 2" cutter. Now a feed rate. At 0.005" per tooth x 4 inserts x 572 = 11.44 inches per minute.
If you had a power feed, then it would be a conservative ballpark tolerance to set it at 10 inches per minute. Since you don't have a power feed (yet), consider the piece is 4" long, so at 10" per minute it would be 4 ÷ 10 = 0.4 minutes or about 24 seconds to make the cut. Make a practice pass above the part to get an idea but just the long side of one rotation of the handle per second.
You'll be shocked at how easy it cuts and how nice the finish comes out.
Oh yeah, try to get a 0.030" to 0.080" depth per pass. Instead of straddling the 2" mill centered on the width of the workpiece, have it cutting off-center by shifting the cutter to have little overhang on the exit side of the cut but no less than center of the cutter in line with the front edge of the block. You don't actually want to be climb milling in the pure sense, but try to avoid straight-up conventional milling with that cutter.