I have a dilemma. I have hundreds of parts that need to be done ideally within a couple of weeks, but my cycle time is hanging around 30 min/part. The machine is a horizontal w/20k spindle. It has plenty of balls and very fast rapids, but it’s a big machine and doesn’t accelerate quickly. 20 min of the cycle is spent roughing (14,000rpm, 275IPM). I am looking at options to cut cycle time so I can get these parts done on time.
One option is changing my toolpath to cut also on the backstroke of the HSM roughing toolpaths, i.e. conventional milling. I tried a test part and it didn’t sound too great until I bumped the RPM up to 20k (500ipm on the test cut in climb milling, 350 in conventional on the back cut).
I am using a Garr end mill with “alumastar” coating, 14k/275ipm was the recommendation from HSM advisor.
I have seen Helical Solutions recommends 16k RPM and up to 1,000IPM on their 3FL endmills. That seems almost too good to be true, but maybe? Another option is Destiny Diamondback, they are around similar numbers with their tools.
If I can cut both directions at higher RPM, I can cut 10+ minutes out of my cycle time, or increase daily part count by 50%.
Sooo… are these endmills really so different that I can run them at twice the feed? Or is it marketing BS? Should I be looking at other options besides these? ALso thinking about a corn cob rougher if I can get the speed, and come back with a finishing mill to clean up.
I have high pressure TSC and using TSC shrink holders for this application.