HIGH SPEED MACHINING - 8 Things You Need To Know!

Barry uses the Kennametal KOR5 Tool to explain the 8 most important things to consider when High Speed Machining.
Help us fund FREE Education by purchasing tools seen in our videos here:
TITANSofCNCTooling.com
FREE CNC Machining Academy:
rebrand.ly/TiAcademy
FREE Aerospace Academy:
rebrand.ly/TiAero
Subscribe for daily content and expert knowledge: rebrand.ly/SUBTITANS
___
___
FREE CNC Machining Academy. Join the Revolution:
rebrand.ly/TiAcademy
Follow us on Instagram:
rebrand.ly/TiINSTA
Like us on Facebook:
rebrand.ly/TiFACEBOOK
Join the conversation on our Facebook Group:
rebrand.ly/TiFBGroup
Connect with us on LinkedIn:
rebrand.ly/TiLINKEDIN
___
___
THANK YOU to our Partners who make this content possible:
Kennametal - rebrand.ly/TiKennametal
DN Solutions - bit.ly/DoosanTiYT
United Grinding - hubs.ly/Q013zHpC0
Mastercam - rebrand.ly/MastercamEDUTiYT
Blaser Swisslube - rebrand.ly/TiBlaser
Tormach - rebrand.ly/TiTormach
Solidworks - rebrand.ly/TiSLDWRKS20
Trumpf - rebrand.ly/TiTRUMPF2022
Trumpf TruMark - rebrand.ly/TiTRUMPFTruMark
Trumpf TruPrint - rebrand.ly/TiTruPrint
Markforged - rebrand.ly/TITAN-Markforged
Tyrolit - rebrand.ly/TiTYROLIT
Mitutoyo - rebrand.ly/TiMitutoyo
Haimer - rebrand.ly/TiHAIMER
LNS - rebrand.ly/TITAN-LNS
FANUC America - rebrand.ly/TiFanuc
Schunk - rebrand.ly/TiSchunk
ONA - rebrand.ly/TiONAEDM
#CNC #Machining #Machinist

[@josephcampise9950]

Barry just seems like the kind of guy you'd love to work with. Very experienced, knowledgeable, and down to earth.

[@barrysetzer]

Hey thanks Joseph! I think most people that know me would agree with you, there. Its all about keeping an open mind, putting others first, and staying humble. I have had guys with less than 1 year experience completely change my processes. Are you a member of our FB machinist group? If so, shoot me a friend request! Ill help out any time!

[@josephcampise9950]

@@barrysetzer I've been a member for a short bit. I'll definitely send one!

[@kryoz8121]

The video when nobody is home: 02:09 The video when my mom comes in my room: 03:01

[@FloweringElbow]

So did I get the basics of 1 to 8 right: have a 100 horsepower, and maximize rigidity? Thanks for the inspiring visuals - impressive!

[@TITANSofCNC]

Well yes, but he said you can use those variables on any machine so long you understand the machine and it’s parameters etc.

[@brahtrumpwonbigly7309]

Basically, nah.

[@FloweringElbow]

@@TITANSofCNC Thanks. Also, I should say your setup is awesome, lighting, multiple cam angles, and clear, clean explanation etc. Appreciate the effort you must put into these videos.

[@tonyjohnson2256]

I use a 3/4 KOR5 endmill on some aluminum parts that I build. The cycle time on our parts went from 15 minutes to right around 5 minutes per part. And with the chip splitter the chip conveyor can easily handles the chips. I even use it as a finishing cutter as well. It holds great tolerances as well thank goodness our finish is not critical. I love the KOR5!!!!!

[@mnucad]

Just Great inspiration to get more from our machines. Thanks

[@tdg911]

Haha haha pixie dust... picked up a couple KOR5 DA and DS from the Titans of CNC store. Love them.

[@TITANSofCNC]

Thank you

[@barrysetzer]

Haha see man, they are monsters!

[@tdg911]

@@barrysetzer pretty cool finish they leave on the floor too. They chew up material so quick I haven’t been able to find the top speed/feed yet lol

[@barrysetzer]

That makes 2 of us 😂

[@travisjarrett2355]

Solid video bro! Great rundown of the things to consider when taking out large chunks of material.

[@duckslayer11000]

More videos like this please. Specifically I would like to hear about the relationship between IPT and radial depth of cut. HAAS glazed over the topic before but they left a lot on the table. Also E.M. feed rates based off of radial step over amount vs full on slotting. Thanks for all the great videos.

[@KnoxGTX]

That is best answered by a cutter representative that can explain it really well. A simple explanation; There is a chip thinning effect with high efficiency milling/high speed milling/dynamic milling… The smaller radial step over, the less angle of engagement the thinner the chip, bigger radial step over the higher angle of engagement and the thicker the chip. Smaller radial step over - increase chip load Larger radial step over - decrease chip load It is difficult to give general speeds and feeds because there are a few things that need to be taken into consideration. Cutter, tool holder, setup rigidity, cnc machine capability, material. We are using a .500in Mitsubishi MEMSS specifically made for high speed machining in P-20. Mazak 510C vertical .875 DOC, .040 radial step over 710SFM @ .0103 / tooth 5400RPM @ 280IPM Spindle load is about 30% No coolant. Air blast only! If you want to transition into high speed machining, you should bring in a cutter representative from kennametal or Mitsubishi and they will help get you started. Edit Worth noting. Software like mastercam have dynamic tool paths that are designed to hold a constant radial step over for a steady chip load. That is why dynamic milled parts have a “wavy” surface finish.

[@duckslayer11000]

@@KnoxGTX great explanation, you would make a good teacher.

[@jiayitoolowen6404]

Great video, wow, the sound of a great milling cutter is so beautiful. I am also going to sharpen this milling cutter so that the customer can cut like in the video too. Thank you for sharing such a great milling cutter

[@trevorgoforth8963]

Another morning, another video filled with incredibly useful info, great job Barry. P.S. The cry baby line was hilarious 😂

[@barrysetzer]

Love you too, Trevor 😂

[@matthewhollenbaugh5138]

It's awesome to hear the processing time from raw stock to that.

[@vonpredator]

Quick! Everyone start clapping for Trevor 👏 👏👏 so he can make more pixy dust! 👏👏👏

[@barrysetzer]

NEVER! 😂

[@trevorgoforth8963]

That’s right Barry, MORE pixie dust! 😆

[@lizzardstuff6436]

lol u just made my morning well Barry that was hilarious 4:58

[@User-th6yy]

Don't forget the rigidity of the Y and X axis needed to do some serious high speed cutting. Our 25 year old machine really struggles to keep stable at some high feed rates, not to mention the inaccuracy when turning the x and y axis from + to - in a circle for example

[@Jessie_Smith]

Great video with a lot of great information as always Barry!

[@barrysetzer]

Thanks homie! You know how we DO!

[@trevor6512]

Now I want to see Trevor and Barry episode of just banter AHAH Great Video

[@BPond7]

It’s a thing of beauty!

[@davegill8634]

Awesome Content Baz 👍

[@MANIEK576]

That is, I'm not the only one talking to the machine to smack me with chips. Greetings

[@rw3468]

I wish I could just buy these tools and use them... but 😮‍💨 I can't spend all my money on tools for my boss lol I do it enough already. Sometimes we gotta make due with what's provided. Love you videos. Thank you

[@barrysetzer]

Hey bro, are you a member of our FB machinist group? If so, shoot me a friend request and I will send a message to you for your boss. If you arent, then JOIN IT and tell them Barry sent you 😜

[@Hydrazine1000]

Barry, if you want to stick to big things, yet not miss the boat on 3D printing / Additive manufacturing, you should look at WAAM, Wire Arc Additive Manufacturing. Or, in lay-man's terms, 3D printing by weld bead stacking. There is a renowned crane builder here that has succesfully 3D printed a set of 350 ton rated crane hooks. 1700 kg (3750 lbs) a piece, about 90 km (56 mile) of welding wire used for each, and they are not a fancy concept, they are Lloyd's Register certified for lifting.

[@barrysetzer]

Haha I may give Trevor a little crap now and then, but he's awesome. And I LOVE additive. I have actually machined parts made by WAAM, as well as laser sintering. That really is the future..........

[@Hydrazine1000]

@@barrysetzer A very big YES on that last bit! (I've got an MSc in Materials Science & Engineering and I've been to the Formnext exhibition and conference on Additive Manufacturing in Frankfurt twice now, so I know what's up. It's one helluva paradigm shift!)

[@williamevans6522]

Incredible

[@user-pr2sn8oo4j]

O, Barry! Glad to see your video! your cutthrouw is awsome!

[@barrysetzer]

Hahahaha thanks bro! Always awesome talking to our brothers from overseas!

[@user-pr2sn8oo4j]

@@barrysetzer hah! i from russia, country with drunken bear and balalayka))

[@Metaldetectiontubeworldwide]

Haha ...popcorn ✅ safety glass on my mobile ✅ Bring ON those MONSTER CHIPS 😄⚡

[@flikflak24]

I like the sassyness in the videos

[@greghartman5895]

There's something about chips flying all over the place that just makes my day. Can't explain it.

[@barrysetzer]

Man i am right there with you!

[@Birb_of_Judge]

7 minutes?! That's insane, i wish I could do something at this at my company.

[@fryer05maverick31]

I'll vouche for the KOR5 cutter, it's a Bad Mama Jama!

[@mp6756]

I have to ask how much stress are you imparting into the aluminum while blasting away material that fast? Do you need to reclamp the stock after a roughing operation so you don't end up with a banana when you release the finish part from the vices?

[@leensteed7861]

amazing mrr

[@fightswithspirits915]

I'm interested in how that stock is made. Quality materials.

[@Sara-TOC]

Is that all it takes Barry? Smack you with some chips? .. 😅 Just Joking. Thank you for another masterpiece! These are great tips for all machinists consider! These tips will enable a machinist to troubleshoot, maximize efficiency, and get the best performance from both machinery and tooling. You and team Titan demonstrate that well! BOOM!

[@barrysetzer]

Hahaha OH YESSSSSS! Thats what it's all about! Machining red pills for everyone!!!!

[@gilbertogarcia1732]

Loved this 😂

[@71mnwild]

The triggering of Trevor was hilarious I must say

[@alex4nder1]

Kor 5 is music in my ears 🎵🌞

[@offplanet6882]

So much to LEARN

[@Kardos55]

Love the fact that everything is always so clean and organized. Nice sound and great visuals . . . oh and you left out the real number one - the master that makes all the magic happen: Barry!

[@barrysetzer]

Ahhhh but without YOU and Mastercam, this video would have been very different! Thanks Karlo!

[@williamofhler5613]

why not 3 vices? that overhang on the ends looks extreme

[@barrysetzer]

It worked tho 😜

[@lonelyplanet1080]

probably because the 3rd one wasn't needed

[@brahtrumpwonbigly7309]

Overkill doesn't hurt, but it is overkill. That material was thick af boii

[@greg2337]

The material was visibly vibrating. I wouldve at least added a machinist jack and hockey puck under it. BUt I cant argue with Barry, it did work without another vise. I wouldve added another.

[@dennischristensen5892]

I kinda begin to think of TITAN as the mad machinist metal shop ;D

[@mohammedalbattal77]

Nice👍👍👍👍

[@dampfexpress]

Yo Barry, since your monster of a machine has a Heidenhain control...have you ever worked with the OCM cycles? I bet you would like it :P

[@barrysetzer]

Hey there! To be honest, I have not! But I do like the Heidenhain control. Finally I can load a program that is longer than 120 bytes LOL

[@dampfexpress]

@@barrysetzer Big Parts - big programs! :D

[@gertkristensen6451]

this machine is monster big and solid ..

[@TommiHonkonen]

Omg when you stepped in the machine I had flashbacks to cribs or something

[@barrysetzer]

HAHAHA well, we really are the KZbin version of “Pimp my machine shop.” 😂

[@ryanjordan7113]

I get amped on nice paths too Barr. However some degrees of excitement we must keep under wraps😂😂

[@barrysetzer]

Hahaha NEVER!

[@ryanjordan7113]

@@barrysetzer it’s one of those corky machinist things. It’s weird; but when you get it, you get it! Looking for a little advice. What’s a really nice hard milling tool you like? Cutting some 4140 right around 46-48 Rc 3303 rpm 15 ipm .001 ipt 5 flute 8mm cutter. Any suggestions are welcome/appreciated. Also on my last EM the one I’m using is discontinued. So I’m looking for a nice good new cutter. Thanks Barry! Wire machine sludge will just never be as cool as big ole shredded chips😂 tell him I’m sorry. Just the way it is.

[@barrysetzer]

@@ryanjordan7113 I am actually cutting some 50-55 Rc steel right now. I am using a Kennametal Harvi 3 Aero. It's a 6 flute that won the Boeing challenge for tool life. I am currently cutting with a .75" tool, 1" deep, stepping over .1", at 2500 rpm and 70ipm. I could probably push it way faster, too. You can also have a look at our store (link in description) so that you can see the pricing.

[@ryanjordan7113]

@@barrysetzer perfect man! Thanks. I’ll check out the link and have the purchaser grab a few tomorrow. These Union carbide 5 flutes were the only tool we stocked in the auto crib for hard milling. So I was asked to source a replacement. Somthing that could be used in a wide range and have reliable life ect… Thinking to myself who’d have the best insight on this, you came to mind right off the hop! Thanks again brotha. Once I get it swapped out and In tune with the work I’ll let ya know how they work out.

[@RMBRacingInc]

If only Kennametal would get safe-lok on the TE end mills. We had to go back to a side lock holder in order to keep the tool from pulling out even with using a HydroForce holder.

[@barrysetzer]

I actually brought that up to some of their higher-ups recently!

[@RMBRacingInc]

@@barrysetzer My Rep has been bugging them like crazy over it. Once you get to that size of end mill it is just necessity.

[@norbertfleck812]

Haimer is also providing that safe-lock feature and some others. If a Hydro-force holder is too expensive, you can also use a Weldon type (the cheapest you can get), heat shrink holders or mechanical Albrecht extreme force holders which even provide a safety lock which makes it absolutely impossible to pull a tool out.. Weldon holders are not too precise, but they are very cheap an still great for roughing at high mrr. It's impossible to pull a tool out of a Weldon holder. I am using right now a Weldon holder to rough mild steel with a 20 mm endmill, 4000 rpm, 1500 mm/min, 15 mm deep, 50 - 90% material coverage. We run that one dry, the monitor shows 15 - 20 kW spindle load. 1 inch is 25,4 mm

[@TITANSofCNC]

I took your comment right to the heads of Kennametal… because I agree with you. If you look closely, the huge full slot videos we do on the NHM are using side lock. Titan

[@highpointsights]

My question is this. Given your outrageous feeds and speeds, do you consider machines expendable? Is replacing them regularly part of your budgeting??? I'm guessing most shops can't afford that?

[@barrysetzer]

It depends on the machines. The machine in this video is meant to be run this way, it's what the machine and spindle were built for. Now, if this were a HAAS, we would consider them expendable. The secret though is that by running fast, you make far more money in 5 years than what the machine cost you.

[@leonschumann2361]

Barry going big but Trevor doing precision work. Like Barry has the size but Trevor can find the G spot ... l mean code

[@barrysetzer]

😂😂😂

[@offplanet6882]

OMG DAM BIG BIG STUFF

[@DolezalPetr]

We got in a job of nightmares, two large steel cubes, far too big for our machine. Normaly my boss would send me drawings and jobs to approve, but this time he just approved this job by himself, he did not even study the drawing propperly, we had to buy special tools for over 2000$ for these large bores in the cubes with huge threads and internal grooves right at the bottom of these deep holes, we had to buy milling cutter extensions to machine all the features on all sides, we had to buy thread gauges to inspect the threads, the cubes were huge and the job was rushed, he gave us only 3 days to finish it, we had to push our machine to its limits, otherwise we would not make it in time. We stopped the spindle 3 times on one cube, machine overloaded like crazy and it still was not enough, we had to send it out to a different company for machining, they had a huge machine that had no problem with it. My boss lost over 3000$ on this one job because he did not consult it with us and it just had to be done for some reason. The next day we tried machining aluminium and we could not take even the lightest of cuts, we discovered that the Y axis was completely clapped out, almost 0,1mm of play in it from trying to machine the steel cubes, just a complete nightmare.

[@barrysetzer]

Oh man! Ive been there, too. Gotta love when someone else over commits YOU. But you gave it your best effort, and that speaks to how good you are, at what we do! 💪

[@DolezalPetr]

@@barrysetzer Thanks Barry, you are the boss! 🤟

[@brahtrumpwonbigly7309]

Darn bosses. He saw dollar signs and didn't look back.

[@jerols-wy6sd]

What do you guys think about Fraisa tools?

[@norbertfleck812]

As there are a few hundred tool manufacturers producing carbide mills, it's unlikely that Barry knows them all.

[@ferryjambul]

how to make a tutorial on how to toolpath for 3d objects to cnc 5 axis

[@zajawamotocykle9256]

Hi Barry

[@barrysetzer]

Hey buddy!!!

[@ferryjambul]

what is the difference between hss and carbide endmills for machining cnc milling?

[@VirusDragovar]

In general, the main characteristic of all High-Speed-Steels is a high working hardness with excellent toughness. HSS tools also cost less than Carbide tools and are often a good solution in ‘high-mix, low-volume’ applications. Carbide is much harder, so it has a longer tool life and faster cutting data than conventional HSS. But the downside of that hardness is brittleness, so the cutting edge on carbide tools can quickly fracture or chip in certain situations.

[@ferryjambul]

which aluminum workpiece is suitable for use and if it is possible that the carbide can break, why?

[@norbertfleck812]

HSS is simply outdated. The price difference is not worth the loss of performance. We use carbide mills for everything from plastics, wood, aluminium, brass, CuAl bronze, mild steel, tool steel, up to hardened steel. Most of our aluminium parts are AW7075 but we also run such speeds even with a much smaller (25 kW spindle) machine. However, coolant is always a good idea if you machine materials with a low melting point.

[@mannydiehard1]

That guy is hilarious 😂

[@jmowreader9555]

Would it have been better to machine the inside first? This would make holding the piece for the second operation easier.

[@barrysetzer]

Machining the bottom actually isn't required. The tool is used to form sheet metal, and the bottom just rests on a table

[@jmowreader9555]

@@barrysetzer Oh, that's cool. Is this for hydroforming?

[@barrysetzer]

Hahaha YES! Surprised anyone actually knew what hydroforming is! You have just received 70 “Barry cool points.” You must be a fellow aircraft guy!

[@jmowreader9555]

@@barrysetzer I used to have REALLY exotic antennas and feedhorns hydroformed out of soft aluminum. Great process, so long as you can find a shop that isn't going to ask you "what the hell is this thing, and why do you only want one?"

[@NJTurboZ28]

Find yourself someone that's looks at you the way Barry looked at those chips!! Lol

[@barrysetzer]

😍

[@user-vw6bw8kr4c]

I feel like most of us machining guys have a similar goofy sense of humor. OR we are super nerdy hahah

[@mrbmp09]

A short tool is a rigid tool. That's what she said.

[@barrysetzer]

Yeah……..pretty sure she didnt say that 😂

[@rameezsheikh7576]

30" (inch)

[@jaylabarre4444]

wich toolpath did you use for this piece ?

[@barrysetzer]

Dynamic Optirough

[@jaylabarre4444]

@@barrysetzer i dont see any retract for Z step .. did you cut it out for the video or how you do that plz

[@barrysetzer]

@@jaylabarre4444 On linking parameters, I used minimum vertical retract, .1" linear entry, .5 horizontal arc entry, .1 horizontal arc exit. Also, on cut parameters page I told it to never retract over gaps, and to keep tool down within 1" distance

[@jaylabarre4444]

@@barrysetzer haa ok soo the movment is just very fast and small i see thx for the info ;)

[@highpointsights]

You didn't show a close up of your milling cutter???

[@norbertfleck812]

Aluminium 6061 does not hurt a carbide mill at all. The only hazard are overheated chips sticking to the tool - filling up the flutes.

[@carlospineda3068]

meh. your MRR decreased the higher in z you went. to avoid that you could've gradually increase engagement. im sure MasterCam can do it right? also, Why explain High feed milling on aluminum.? its easier to spot the advantages of it on More exotic metals.

[@frankf.7970]

👏🙆‍♂️💗

[@kravselj]

it's simple to run these simple test parts with constant load like this. But in real life when you have real parts it's not that simple.

[@hamzanawaz7945]

Boooooom

[@RT11714]

Trevor was indeed very sad

[@alexc5564]

This is the cool shite 😎😎😎

[@Talinthon]

I'm gonna call your bluff. I want to see this one cutter make literally 1000 pcs of this part.

[@barrysetzer]

Lol, come on man. Its ALUMINUM.

[@Talinthon]

@@barrysetzer Actually, I just want to see if you'll go crazy doing the boring production stuff.

[@dadtdm5646]

@@barrysetzer - Even so 7000 minute tool life....probs not 🤠

[@shbooby5258]

3:03 if you don’t talk to your machine like this your not doing it right!

[@barrysetzer]

Hahaha YESSSSSS. This guy GETS IT

[@dan3076]

unclamp it and....... BOING

[@beachboardfan9544]

Y'all should've labeled this nsfw! 😆

[@DolezalPetr]

true XD