Hi speed milling 6Al-4V titanium?
Hi speed milling 6Al-4V titanium?
(OP)
I have an application to mill 2mm square "windows" thru 1mm thick 6Al-4V titanium. The "windows" require .5mm corner radii, so I plan to use 1mm dia carbide end mills. Quantities are 3,000 parts with 250 "windows" per part. I have CNC spindle speeds available to 30,000 rpm. Does anyone have any suggestions as to how this might be handled? Any thoughts about speeds, feeds, depths of cut, expected tool life etc...
Thanks,
Dave
Thanks,
Dave





RE: Hi speed milling 6Al-4V titanium?
But:
If you must use an end mill, you'll likely have to pre-drill a start hole in each window. Even if your end mill claims to be center-cutting, I think you'll find it unsatisfactory for that purpose, in terms of tool life. Drills are MUCH better at making holes from the solid than are end mills.
My data suggests a starting speed for the end mill around 100 SFM, which would translate to 9700 RPM for a 1mm tool. Feed of not more than .0001 IPT (and possibly much less) - a two-flute end mill would thus feed at 1.94 IPM.
I think you'd be unlikely to finish even one complete part without catastrophic tool failure.
RE: Hi speed milling 6Al-4V titanium?
RE: Hi speed milling 6Al-4V titanium?
Thread281-48509
RE: Hi speed milling 6Al-4V titanium?
Can Ti be cut with a water jet?
Keep the wheels on the ground
Bob
showshine@aol.com
RE: Hi speed milling 6Al-4V titanium?
RE: Hi speed milling 6Al-4V titanium?
I did find exceeding 100SFM was nearly impossible.
Dave
RE: Hi speed milling 6Al-4V titanium?
Thanks for the update on your project. Which company's inserts did you use for this? Coating type? Coolant? It would be nice to have all of this together with your speeds, tool life, etc.
RE: Hi speed milling 6Al-4V titanium?
Dave
RE: Hi speed milling 6Al-4V titanium?
RE: Hi speed milling 6Al-4V titanium?
Is EDM an acceptable alternative for these parts?
We used to just machine the electrodes out of graphite and burn a dozen or so screens at a time.
The graphite machines quickly and a whole lot easier than Ti. On our parts the windows .187" x .187" were about .020 apart and grids of 6" x 6" at about 25 degrees.
You might have to do a thinner stack with the smaller windows
Talk to your local EDM job shop. Should be a no-brainer for for them.