A challenging task, I seek help from you guys!

[Manohj Kumaar]

I got a 60 mm Idol to machine in Pocket NC using Copper alloy. I have got a similar task which was done successfully using wax. Actually the material got some porosity, is it recommended to machine it using pocket nc? If recommended please help me out with some machining strategies 

[Manohj Kumaar]

I am using 5 mm 4 flute end mill and my settings are 0.2 mm doc, 0.5 stepover and 10000 RPM with 100 mm/min. Can I improve it? For my settings the machining time is too much which is more than a week!

Please help me out

[Tokyo Pav]

Are you using adaptive clearing for the initial roughing? You can take a deeper depth of cut with small radial step per tooth to speed up the roughing. I would be worried about the copper bending with finishing cuts so maybe it would take a long time to get a good result unless you can at some supports so you can increase the size of cuts then cut them off as a final operation. 

Wat operation styles are you using for finishing? maybe post an image of the cut sequences you have and we can make some suggestions.

Regards

TP

[Manohj Kumaar]

Thank you very much @Tokyo Pav!

I am not sure about the material behavior so I used pocket clearing for roughing and not good at doc and stepover too. I planned to do contour finish and morph spiral finish but I still stuck in roughing stage itself. @Tokyo Pav how much doc and side load you suggest for adaptive clearing please so I can go for it

[Tokyo Pav]

Hi Manohj

Typically you take 2-3 times the diameter of the tool as a depth of cut and reduce the step over to maybe 5-7% of the tool diameter. Increase the feedrate 2-3 times also. One of the biggest benefits is that you should be implementing is the ability for low height transfer at the maximum machine feedrate. Moving to a clearance plane will dramatically increase the operation time so try to avoid that.

Below is a formula to help understand radial chip thinning and how to calculate feedrates for adaptive(constant tool load) operations.

Regards

TP

[Manohj Kumaar]

Thanks for your help @Tokyo Pav