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Lab talk, the good, the bad, and the ugly
Equipment
Beauty Zir Milling Burs
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<blockquote data-quote="CoolHandLuke" data-source="post: 322491" data-attributes="member: 4850"><p>ah, so its chipping that you are trying to fix?</p><p></p><p>this can be a lot of things but i'll try to jot them all down. if i leave anything off then someone else will point it out no doubt.</p><p></p><p>1. clean and properly lubricate your machine; in the old DWX50 you had to grease the rails from time to time, consult your machine's handbook as to this maintenance.</p><p></p><p>2. address any vibration in the machine. example: i worked at a place with 2 mills on the same steel table, this caused both machines to wobble while in use. this wobble translates directly into tool deflection and chipping or breakages.</p><p></p><p>3. perform a collet cleaning and get your runout checked with a gauge. most collet cleaning kits contain a pin for use in securing the collet while tightening so that the fingers of the collet don't deform or break. use this pin in your runout checks. you absolutely do not want > 0.005mm runout over 10k rpm because with limited engagement tools like the 1mm finishing tool, this makes for a 10% increase in engagement, which means the tool gouges the workpiece and can dig in, insodoing while the tool might not break, it will try to rip a chunk out of the material or cause a chip.</p><p></p><p>4. calibrate your machine. it is known that some machines have touch-off issues, the machine picks a tool and touches the sensor but due to wear in the sensor, the machine understands a faulty value for the tool length. this leads to breaks all over the place, and while i'm trying to recall the name of the machine this is most problematic in i think its Wieland? other users may be able to pinpoint this for me.</p><p></p><p>5. this ones the difficult part: if the machine is still chipping after all the maintenances then you should have your CAM provider take a look at the CAM to see if there is a way to revise the speeds, feeds, or engagement for better tool life. if you have a roland, use your vpanel to turn the spindle speed down 2-4k rpm (usually 5-10%) and see if you notice a change. lower rpm means lower tool runout but also means larger cuts, which is why you'd only want to trim off 5-10% of the speed at most.</p></blockquote><p></p>
[QUOTE="CoolHandLuke, post: 322491, member: 4850"] ah, so its chipping that you are trying to fix? this can be a lot of things but i'll try to jot them all down. if i leave anything off then someone else will point it out no doubt. 1. clean and properly lubricate your machine; in the old DWX50 you had to grease the rails from time to time, consult your machine's handbook as to this maintenance. 2. address any vibration in the machine. example: i worked at a place with 2 mills on the same steel table, this caused both machines to wobble while in use. this wobble translates directly into tool deflection and chipping or breakages. 3. perform a collet cleaning and get your runout checked with a gauge. most collet cleaning kits contain a pin for use in securing the collet while tightening so that the fingers of the collet don't deform or break. use this pin in your runout checks. you absolutely do not want > 0.005mm runout over 10k rpm because with limited engagement tools like the 1mm finishing tool, this makes for a 10% increase in engagement, which means the tool gouges the workpiece and can dig in, insodoing while the tool might not break, it will try to rip a chunk out of the material or cause a chip. 4. calibrate your machine. it is known that some machines have touch-off issues, the machine picks a tool and touches the sensor but due to wear in the sensor, the machine understands a faulty value for the tool length. this leads to breaks all over the place, and while i'm trying to recall the name of the machine this is most problematic in i think its Wieland? other users may be able to pinpoint this for me. 5. this ones the difficult part: if the machine is still chipping after all the maintenances then you should have your CAM provider take a look at the CAM to see if there is a way to revise the speeds, feeds, or engagement for better tool life. if you have a roland, use your vpanel to turn the spindle speed down 2-4k rpm (usually 5-10%) and see if you notice a change. lower rpm means lower tool runout but also means larger cuts, which is why you'd only want to trim off 5-10% of the speed at most. [/QUOTE]
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Lab talk, the good, the bad, and the ugly
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Beauty Zir Milling Burs
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