Face Milling 1018 Steel w/K-Tool OCTA Mill - Tormach CNC

Tormach on the web @ http://www.tormach.com

Overview:
A 3/4" steel plate is finished on both sides. One side is a surface cut, the second side has 0.2" removed using 1.5" diameter face mill with high positive angle inserts.

This video reviews a surfacing operation using a high performance insert face mill. The task involved both sides of an 8" circular plate, one side with a simple finish cut, the second side removing 0.200" at 0.050" per pass.

Material: 1018 Steel
Cutter: K-Tool Insert Face Mill
Model OC-1575
Inserts: OPEB 535XP GR-X40
Speed: 1500 RPM
Feed: 10 IPM
Machine: Tormach PCNC 1100

Background:
Modern inserts with a high positive angle of rake allow high rates of metal removal with minimum power. High positive angle reduces the cutting forces, thereby reducing tool flex, horsepower, and improving finish. Longer machine life, reduced vibration, and higher metal removal rates are among the benefits found with high positive cutters.

Read more:
http://www.tormach.com/MfgDatabase/20106_Surfacing%201018_Steel.pdf

Key words:
Tormach, CNC, 1018, steel, mild steel, face mill, insert, insert mill, high positive, rake angle, surface mill, stock removal, K-Tool, OCTA cutters.

Category:

Science & Technology

Tags:

• Tormach
• CNC
• 1018
• steel
• face
• insert
• mill
• high
• positive
• k-tool
• OCTA
• cutters
• rake
• angle
• surface
• stock
• removal

[jozsef123]

why did you use coolant with a roughing cutter?

[tormachllc]

Roughers generate less heat than a conventional tool, but it's still important to use coolant. The tool will last longer and can be driven harder when the cooling and lubrication properties of flood coolant are present.

[tormachllc]

When using carbide insert cutters there are different opinions on when to use coolant. Some carbide insert manufacturers say not to use coolant because of the thermal shock on the cutting edge being heated by cutting then cooled quickly by the coolant causes premature insert failure. I have found from experience that this is true some times.

[tormachllc]

In the video the part was getting very warm and heating up the turntable. I tried the coolant and did not have trouble with the insert failing so I used coolant to keep the temperature under control. I was able to machine 12 plates and the inserts showed wear but still had some life left in them. Some grades of carbide would have failed on the first part using coolant. The grade I was using was not affected by coolant. Under ideal cutting conditions not using coolant is the best thing to do.

[cncsimple]

Download free utility for create cnc code for face milling at : cncsimple[.]wordpress[.]com

[jestephens]

@HertzCOD4

I agree, Hertz. Those chips don't show any color at all; probably not carrying away any heat for the cutter. A 45 deg lead endmill like that should be feeding quite a bit faster due to the chip thinning.

[HertzCOD4]

If you are getting heat in the part, its clear that you are not feeding fast enough. Get the heat into the chip. You don't need coolant for that application, good lord. You are feeding so damn slow. lol

[Luvanicebum]

I DO NOT use coolant on 3 flute tinc coated carbide

end mills or ceramic inserts. These coatings are

far too hard and susceptible to thermal shock.

I only use coolant to cool the part after milling or turning

before finish passes.

[Luvanicebum]

Also to reduce heat in the part, so you can move quicker to a finish pass if you have tight tolerances +/-.0003

Otherwise, carbide is made to take the heat.

I run a 2" shell mill, full width cut into 4150 HR steel at

1800RPM/12ipm/.060" per cut, leaving .015 for cooling, then a .010" pass, leaving .005 for finish pass.

All this on an old Servo Mill with only mist coolant not flood.

[jozsef123]

thank you for explaining...i was just asking cuz i work in a tool and die shop and the cnc guys don't use coolant on ther roughing cutters