Make Parts Faster, But Also Not Slower -- Ep. 80

Harrison and AJ delve into the intricacies of machining, sharing their experiences, challenges, and solutions. Harrison discusses the use of roughing and finishing tools, highlighting the importance of addressing scale buildup and tool breakage. He mentions the use of specific tools for different materials, like aluminum and stainless steel, and the nuances of achieving desired finishes.
The conversation shifts to workholding, with Harrison recounting a frustrating experience with acquiring matching vices for a job. He explains the need for precise alignment and the challenges posed by different vice heights and jaw thicknesses. Despite these challenges, he describes his approach to problem-solving and the satisfaction of finding solutions that improve efficiency and quality.
AJ contributes to the discussion by sharing their process for making carabiners. They detail a fixture that allows for efficient machining operations, including profiling, slotting, and chamfering. They also mention recent improvements to their process, such as using water jet-cut blanks and custom cam clamps for workholding.
/ tapsandpatience

[@AudacityMicro]

Our sound issues came back 😢 But we know what is causing them now! just need to figure out how to solve the issues once and for all

[@JMG_Manu]

Just for reference: I'm running my Haas 3/8" 6FL ( P/N 03-2140 ) at in 304SS. SFPM: 480, .003" chip load, .375" DOC, .0375 RDOC. At 6 hours cut time currently and haven't replaced the tool yet. Haas VF4, Haas milling chuck, and Mastercam dynamic milling toolpath.

[@JMG_Manu]

Also check out Nexgen Tooling, I've had great success in 303SS with their tools. Ran the 3/8" 6FL square corner through 100+ hours of .1DOC slotting at 250SFPM. I fully expected the slotting to destroy that tool given the square corners. This was on my 96' Fadal VMC15

[@viliusr6974]

I feel the pain with the tooling issue. I had a job which looked relatively straight forward, but needed a lot of material removing. Two expensive tools I bought did not justify their price - the tool life was nowhere near the the promised, everything had to be dialled down. What I ended up doing - bought a whole box of cheap highest spec inserts from far east, and a second tool holder, and was just swapping the tool with new set of insert edge (4 edges per insert) every hour and a half (machining time per part), while running the job at 1.5x max feeds and speeds from tungaloy tables. And the nicest bit about that - no stress! swap material, swap the tool and press the cycle start button. Also, if the the geometry has V notch type pockets, conventional cutting might work better for the tool life.

[@Chris-nt9lk]

For my cnc’s I had built a new section on to my shop, I left a 9’x10’ section of wall open to bring my machines in to the new section. Once machines where in I closed up, complete with drywall and insulation. If I have to open it up in a few years no big deal… to much heat loss during the winter here to have more garage doors than I need to use all the time. Just open up a wall and bring in a machine if you need to then close it back up.

[@RAT7163]

Hey I liked that super glue video, don’t get discouraged.

[@nocturnalwelding5166]

Love the new music🤘🤘🤘🤘🤘🤘🤘

[@ashtongriffiths8373]

This might sound weird but I had similar problems in 316 using a 2.5" SECO face mill and what worked on that job was turning the coolant off?!? I have no clue why but I was getting way better tool life.

[@AudacityMicro]

Interesting! Maybe thermal effects?

[@ashtongriffiths8373]

@@AudacityMicro Really not sure but all the heat was in the chips the part was just warm.

[@AudacityMicro]

I meant that the tool life may have been decreased due to thermal shock, caused by alternating hot cutting, with cold coolant. It can hurt tool life in some materials. A lot of people run mild steel dry now because of that.

[@SecondFloorOutdoors-gj8dt]

Are you using the same tool edp for the facing as the hat removal? If the 3/8 5 flute is holding up good, why not use it for the whole op? I wonder if the material is sticking and not being evacuated. 300 series loves to stick and gall, especially if you're using water soluble oil.

[@SecondFloorOutdoors-gj8dt]

Guess that answers that. Chipped corners sounds like built up edge. Higher concentration on your coolant or a different coating to reduce sticking?

[@rodneytodd3187]

Have you tried a bull nosed em, low SFM & deep cuts

[@vanguard6937]

oh man, what day was harrison there? i would have loved to meet up and talk shop for a bit

[@AudacityMicro]

I think he went today?

[@FreakyClimber0707]

So it looks to be that Kurt vises are what most of the haas vises are. The haas vises are not much cheaper then just buying directly from kurt.

[@lpfreak1708]

The theme song at the end sounded like a Volbeat song lol

[@AudacityMicro]

I'm pretty sure that one was supposed to be like AJR.

[@oldmetalmachines2094]

No coolant is the key with 304. If you have an interrupted cut it makes it worse

[@yelims20]

get some inconel 718, see what your speeds and feeds LOL... Mat'l only cuts so fast. You missed your quote.

[@AudacityMicro]

I've got some ceramics to cut soon. The suggested SFM is 25 😳

[@yelims20]

@@AudacityMicro ok, you have to cut some ceramic. I thought you were saying ceramic tools to cut 304... I get it. I used to have to made somethings from a machinable ceramic that got heat treated after...

[@yelims20]

ceramic cutters?

[@yelims20]

hardened 304... okay... sounds more like you got some 321 or 347 stainless 225 sfm is as good as I've ever done in 304

[@piotrk4351]

Please give us links to all the theme songs ;-)

[@AudacityMicro]

suno.com/playlist/77a9bd65-0afc-4ecb-93d2-d0ef2e9b26e2 This should work

[@jrvm77]

600 sfm. Is way too fast for 304 If you go by the book it should be 265 max and .003 IPT

[@AudacityMicro]

Tools, coatings, carbide, and coolant is getting better, so I think you have to allow for some SFM inflation over the classic numbers. But yeah, I agree. I tried to tell him 😂 -AJ

[@jrvm77]

@@AudacityMicro he’s more worried about run time then making a good part, broken tools is the worst feeling, you start doubting your self of your program or set-up

[@LoneWolfPrecisionLLC]

600 sfm is not to high. I did tons of testing the the Harvey 4 so much so that we got noticed by kenemetal. 600 sfm and about .005 fpt was about were we landed. Made over 2000 pounds of chips with 3 cutters and one box of face mill inserts.

[@LoneWolfPrecisionLLC]

Aj you should look at moorside fixtures you can sudo 5axis with a 4th. Also i would consider a brother with a nikken trunnion for a 5axis.

[@Chris-nt9lk]

The moreside fixture is a nice cheap option… and very easy to make yourself when you have the machines… or just save time and buy

[@AudacityMicro]

I will look into those. Thanks!