Tool Path and Tool Choice

CAD/CAM/CNC
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Hello,

I need help communicating to a co-worker there are better ways for us to machine this part than the way he’s doing it. This part is approximately 16" long x 5.5" wide at the widest x 5" tall and will be milled out of a single block of 6061 aluminum.

I do not want to talk down to my co-worker. He’s a very smart guy but he’s not seen what I’ve seen and I know what CAN be done, I just don’t know HOW it’s programmed to explain what I’m trying to get across to him, if that makes any sense.

Currently he has the entire profile cut with a 3/4" insert end-mill.
I feel it would be much quicker to use one of our 3" Sandvik shell cutters to plow out the bulk of the material and then use the end-mill to do the finish work.

I know I’m leaving out a ton of specifics but I’ve got to run for now. We’re using a HAAS Super Minimill to cut this thing. 10k spindle, flood coolant only.

Thanks for your help.

Karl

2

You can utilize a face mill as a large endmill, you have to be careful of any draft or angle in the inserts, a 90 degree face mill should work. Be careful of the length/overall depth of cut and not have toolholder collision… Probably could run an adaptive contour.

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In my opinion, on a Minimill , you will work quicker by a 1" 5xD solid mill and adaptive strategy.
With a 3" mill, maybe you will decrease the axial step over for torque requrements.
Take care.

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