Simple aluminum project

[likeablebump]

I cut out these brackets on my Power Route tonight. Several different tools were used. 

1/2" 4 flute flat end mill @8,500rpm for a facing operation --- .010" was removed at 33ipm and .4 stepover
1/8" 3 flute ZRN coated flat end mill @22,000rpm in an adaptive operation to drill the holes --- 18ipm - .0175doc - .0375woc
1/8" 60deg. engraving bit @18,000rpm for the letters --- 15ipm - .020doc (I should've ran this toolpath twice. The letters have some burrs in them that I will have to manually remove.)
1/4" 2 flute flat end mill that came with the machine @18,000rpm, contour toolpath --- 33ipm - .0175doc - full width slot

I feel like I'm still running conservative on my feeds and speeds. I'd appreciate any input. I had this aluminum given to me, but I'm pretty sure it's 5052. It seemed softer than the 6061 that I've machined.
I used an air blast for most of it with an occasional spray of WD40.

[blinsc]

I think you're in the ballpark for reliable operation. When cutting aluminum with the PR, the DW618 router will bog before the machine hits its limit and for this reason I tend to stay away from 1/4" or larger end mills, and also because a lot of what I do requires small-ish holes or corners that a 1/4" can't get into anyways.

My favorite bit for aluminum on the PR is the 1/8" Onsrud 63-610 but I suspect any good single-flute designed for aluminum would work. I use .002 chip load at 18,000 RPM (36 IPM) and .020 DOC for 2d contour. For adaptive with that end mill I use .010 optimal load and .250 step down but that can probably be pushed up if you're doing a shallower pocket.

[Derek the Admin]

I would use 6061 as your baseline to work from. 5052 is so gummy by comparison. That is part of why you saw the burring on the letters. Have you seen the cut setting calculator at www.millrightcnc.info?

Regards

[likeablebump]

Apr 26, 2020 22:09:43 GMT Derek the Admin said:

I would use 6061 as your baseline to work from. 5052 is so gummy by comparison. That is part of why you saw the burring on the letters. Have you seen the cut setting calculator at www.millrightcnc.info?

Regards

I am mostly cutting 6061. I had a piece of this given to me about 8ft. long and 8in. wide so I figured I would try to turn it into something. On my second try I ran the engraving operation a second time .010 deeper and it cleaned it right up!

Also, I have used the millright calculator a few times and it seems to work quite well. I've also been using g- wizard. So far I've been having good luck. I've only messed up a couple of bits.

[Derek the Admin]

Sounds like you are moving along well.

Cheers
Derek

[likeablebump]

Apr 26, 2020 22:09:43 GMT Derek the Admin said:

I would use 6061 as your baseline to work from. 5052 is so gummy by comparison. That is part of why you saw the burring on the letters. Have you seen the cut setting calculator at www.millrightcnc.info?

Regards

The cut calculator assumes a slotting operation, correct? I just attempted to run a 2d contour with an 1/8" 3 flute bit using those numbers and it snapped a few inches into the cut. The numbers seemed pretty aggressive but I figured I'd give it a shot. I guess that's how you learn.