Dynamic feeds and speed

[gcode]

I'm programming a job on a Haas V2 with a 10K 20hp geared spindle

The last time I programmed a Haas, dynamic milling didn't even exist.

I need some advice.

I know the best advice is to use a stronger machine, but you go to war with the army you have, not the army you wish you had.

Material is 316L

Tool is a Helical 3/4 endmill P/N 83009  3/4 x 1.25 loc x .03R 5 flute in a hydraulic holder

desired length of cut 1.100  with .070 stepover

I've tried a number of sources for feeds and speeds and they are all over the map

Helical Machining Advisor says  2390 rpm at 255 ipm

HSM Advisor says  1971 rpm at 64 ipm with an over torque warning

GWizard says 2342 rpm at 83 ipm  with the slider.

We got a lot of parts to build and it's important to get this right

Any help would be appreciated

TIA

[neurosis]

Is there any reason that you're married that that large of a diameter of end mill?  That cut depth doesn't require that large of a diameter and you'd probably get better results taking advantage of a smaller diameter with a lighter step over.  You could increase the sfm and feed rate and probably end up with a decent mrr without taxing the machine.

[byte]

Neuro makes a good point,  the big diameter endmills aren't always your friend where spindle power is an issue,
here is a video from youtube in stainless steel with a .500" tool cutting 1" deep 316
">

The parameters are

1/2" Endmill with vaiable helix, variable pitch. Axial depth of cut = 1.0 inch / radial DOC = .100 max. Base feedrate = 80 IPM / RPM = 3500.

I think for that material I would run about 2k at 50 ipm for those full depth high-speed type cuts, thats with a metal bar sticking out of the vice so not a rigid setup, I would work my way up from around that with a half inch tool, your step over is so small I think its better

[gcode]

Thanks guys
I answered at length on eMC
This is really discouraging
I quoted this job to run at our shop on a 3 year old OKK VMC with a  geared 10K 40hp BigPlus Cat50 spindle
Management decided to run it at our recently acquired job shop full of Haas VMC's, most of which
are ready to be put out to pasture.
I've tried to tell them my quote won't hold and the whole project may end badly but these guys
live and die by spread sheets.
This part also has a .7500 ± .0005 thru hole ( 3.955") and before you ask, there is no thru spindle coolant
on these machines  

[Rstewart]

Stubby tool holders will help the Haas.  If you're ruffing, put it in a sidelock, save the hydraulic for finishing.

I usually try and stay 5/8" and under in the endmill department, although that 3/4" isn't too bad.

[gcode]

Tom - on the bright side...you're not long from retirement now 😁

9 days

My plan has always been work till 70 but...

[Jeff]

HSM Advisor says  1971 rpm at 64 ipm with an over torque warning

If you change the stepover to 5%  (.0375") You will have more MRR than if you went with .07 stepover.
496SFPM and .01656 IPT
This is assuming a stickout of 1.35" from the holder.

[CADCAM396]

if it is an older Haas watch out for clipping of corners and radius overun.
use what ever high speed look ahead options you have and allow appopriate amount of stock for cleanup.

[Tim Johnson]

:_thumbup:

HSM Advisor says  1971 rpm at 64 ipm with an over torque warning

If you change the stepover to 5%  (.0375") You will have more MRR than if you went with .07 stepover.
496SFPM and .01656 IPT
This is assuming a stickout of 1.35" from the holder.

[gcode]

update
I proved out the first roughing op yesterday
material was 316L stainless steel
I ran a 5/8 x .062r x 1.25 LOC 5 flute endmill @ 2000 rpm, 50 ipm, .05 stepover and 1.1 DOC
The machine was a relatively new Haas VF-6 with a 30 hp 10K geared spindle running in low gear
The holder was a stub length Weldon endmill holder
Time in cut 6 minutes
The load meter was at 40% but spiked to 60% a couple of times
There was no visible wear on the endmill
Chip evacuation is going to be a real problem.
There were 4 coolant lines going and they were totally inadequate.

This machine has a safety interlock on the door which prevents opening the door
while the spindle is turning.
You can't open the door and blow the chips clear while it's in the cut.  


thoughts on running air blast on stainless steel
the machine doesn't have air blast but we could rig something up

I'm also think about rigging up a garden hose with a jet nozzle

https://www.dropbox.com/s/w0z2htpzvug8d4b/chip_troubles.jpg?dl=0">Chip trouble

This is the result of roughing a pocket the an Ingersoll button cutter using a contour ramp @ .050 pitch
I had to break this toolpath into 5 segments with program stops to clear chips

[Jeff]

Chip evacuation is going to be a real problem.
There were 4 coolant lines going and they were totally inadequate.

Sounds like you could use an endmill that has a chipbreaker. I can't remember which mfg's make them at the moment because it's 6:30 am, but find one that has the tiny little notches in the flutes, it will cut down on the chip  volume drastically.

[Rstewart]

update
I proved out the first roughing op yesterday
material was 316L stainless steel
I ran a 5/8 x .062r x 1.25 LOC 5 flute endmill @ 2000 rpm, 50 ipm, .05 stepover and 1.1 DOC
The machine was a relatively new Haas VF-6 with a 30 hp 10K geared spindle running in low gear
The holder was a stub length Weldon endmill holder
Time in cut 6 minutes
The load meter was at 40% but spiked to 60% a couple of times
There was no visible wear on the endmill
Chip evacuation is going to be a real problem.
There were 4 coolant lines going and they were totally inadequate.

This machine has a safety interlock on the door which prevents opening the door
while the spindle is turning.
You can't open the door and blow the chips clear while it's in the cut.  


thoughts on running air blast on stainless steel
the machine doesn't have air blast but we could rig something up

I'm also think about rigging up a garden hose with a jet nozzle

https://www.dropbox.com/s/w0z2htpzvug8d4b/chip_troubles.jpg?dl=0">Chip trouble

This is the result of roughing a pocket the an Ingersoll button cutter using a contour ramp @ .050 pitch
I had to break this toolpath into 5 segments with program stops to clear chips

G.  All you need is a magnet to beat the prox switch, I use one all the time on newer Haas.  Yes, their coolant pressure isn't up to par.