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  1. #1
    Join Date
    Jul 2014
    Posts
    3

    Unhappy Speeds and feeds

    I make a 3.5 in. bevel gear out of C954 AL BRZ on a regular basis. I surface the gear teeth on a 4 axis VMC. I can cut them all week long with the same end mills @ 6K rpm and 35 ipm. My customer wants some out of 1040 CRS. Roughing the stock is no problem, however finishing is a different matter. I'm using an ALTIN coated 1/8 ball mill @ 6K rpm and 7.5 ipm. My semi-finish pass is taking approx. .005 stock off. I can only do about 5 of the 15 teeth before the end mill goes away. Any advise for speed and feed? Thanks

  2. #2
    Join Date
    Jul 2014
    Posts
    18

    Re: Speeds and feeds

    Your feed rate is very low. 0.00125 per revolution. This will cause the tool to wear prematurely. Assuming not plunging the tool into a corner and good coolant supply (Air preferred... mill steel dry!!) Safely double your feedrate to start. I would run this tool at 12,000 rpm and 24 IPM and increase feed from there. The important thing is NOT to recut the chip. Use plenty of air to get it out of the way.

  3. #3
    Join Date
    Jul 2014
    Posts
    3

    Re: Speeds and feeds

    Thanks for the info. I have an 8K spindle, using your numbers I came up with .0005 IPT. So if I run at 7200 RPM x 4 flutes x .0005 IPT that comes out to 14.4 IPM, correct?

  4. #4
    Join Date
    Jul 2014
    Posts
    18

    Re: Speeds and feeds

    That is correct. If the depth of cut is only at the tip.... then increase from there to account for chip thinning. Ball mills are their own animal. Feed is dependent on axial DOC.

  5. #5
    Join Date
    Aug 2014
    Posts
    12

    Re: Speeds and feeds

    Find out the recommended surface footage of that brand of tool you are using. take the surface footage x 3.82 / dia.. this gives you the recommended rpm.. take the rpm x ipt x # of flute.. thats your feed rate..
    If you have a decent end mill the surface footage will be about 200 with a chip load of about .001 per tooth..
    s = 6112
    f = 24.

  6. #6
    Join Date
    Apr 2012
    Posts
    90

    Re: Speeds and feeds

    Go 8000 rpm and 48ipm if you are using a 4 flute ball increase feed if you are able to. You can use coolant if you have high pressure flood otherwise cut dry with air for chip removal.

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