Broaching in a CNC Mill. Our Guides for Specific Materials includes articles that have tips, techniques, and feeds and speeds information for specific materials. Feeds and Speeds for Composites: Material Guide. Feeds and Speeds for Wood: Material Guide. Guide to Choosing Types of Metals. Plunge Roughing : Try this special technique when rigidity or machine performance are making things difficult.
Micro-Machining : How to avoid breaking those tiny little cutters. What is Cryogenic Machining? Learn the advantages of using Liquid Nitrogen as a coolant. Chip Thinning and Other Ways to Speed Your Cuts : Learn about cases where you should be upping your speeds and feeds and how to exploit them. Tips for Improving Surface Finish on Mills. Milling Tough Materials. Feed Rate Formula:. Other Milling Cutting Speed Formulas:. But like so many things, there are a lot of exceptions where just following the simple math will get us into trouble.
The blue shows how much thinner shallow cut chips are versus full width red segment. This may seem pretty harmless. At worst, it seems like using these thinner cuts may be leaving money on the table. However, chip thinning taken to the extreme can be very hard on tool life.
The reason? So, they keep the Cut Width very light. I manually bumped the chip load down from the chip thinning-adjusted value G-Wizard would normally give. Now G-Wizard is giving me a warning:. Chip thinning can drive down chip load so low that the tool begins to rub instead of cutting.
I even did a video on chip thinning for Cutting Tool Engineering. The Cutting Speed Formula may be simple once you have all the parameters, but finding the proper values for the parameters is a lot harder than it looks. Not good, right? Now for starters, it sounds to me like they have that backwards. Less Depth of Cut means you can afford to be more aggressive. But, even correcting for that, what are we supposed to do when Axial Depth is say 0.
Tables are only good for showing 2 dimensions. They add rules like the ones described to try to make things more flexible and fit the cutting physics better. But, the actual cutting physics are quite complex. You need to smoothly adjust your surface speed and chip load for every possible point on the 2 dimensions that make up Cut Depth and Cut Width. It has to be a calculation. Many manufacturers realize this and wind up telling the machinist that the catalog values are just a recommendation and that the machinist will need to use their judgement to decide exactly where on the range of values they should be for a particular cut.
One of the great wonders, if you think about it, for hobbyists is they can buy and use the exact same cutters as professionals. In fact, you may need to adjust even when comparing Feeds and Speeds on two different industrial machines. This is true for all sorts of reasons such as:. You get the idea. How can we compensate for lack of rigidity on a lightweight machine? Back solving can be very important where machine limits are encountered.
Sometimes we need to work backwards from a limit to see how it affects all the other values in the calculation. But, making formulas work in reverse, especially when we have a large and complex network of intertwined formulas is not easy.
It requires very sophisticated math to make it all work out. In fact, even a spreadsheet, as powerful as they are, has a hard time with back solving.
You will need software that can do it directly. High pressure through spindle coolant can really change speeds and feeds…. The two most important purposes are chip clearing and lubrication. We all hate when that happens. But all coolant is not equal. For example, coolant needs to be aimed properly. They make technology in the form of Programmable Coolant Nozzles to facilitate proper aim.
If using CD players then you will also need two. You will need two CD players in order to play two songs at the same time and work to beatmatch them. Choose two songs that you know very well.
These are the songs you will first try to beatmatch. It is best to choose two songs that you know well because it makes it easier when first learning how to beatmatch. Adjust your headphones so that they cover one ear and play track B.
This is so that you can hear track A through the speakers and track B through the headphones. Track A would be the song playing to the audience and track B would be the next song in the set if you were performing. You should also turn off or cover up the BPM and waveform readers with sticky notes.
The point of this exercise is to learn how to beatmatch by ear so using these readers would be cheating. Cue track B on the first beat of a bar. Find the first beat of the song by starting to play the song and then stopping the record as soon as you hear the first beat.
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