Hi Jason with Tormach. Today we're machining titanium. We wanted to freshen
up our logo plate a little bit, and decided that we should definitely
machine this out of titanium. So we partnered up with Harvey tool on this
project. So let's jump into the cutting talk, about speeds, feeds, workholding, and
all the challenges that we faced along the way, So let's go make this.
Alright, so let's jump into the cutting here. As you can see, it's a twelve by six
inch, three-quarter thick, commercially pure grade, two titanium. We mounted it to
a fixture plate using super glue, and the blue painters tape. I always kind of wanted
to try it on a bigger, harder to machine piece of material, and it worked for us.
We did run into a couple of problems that I'll point out here in a second. So
you can see we're cutting. We have a 3/8 inch cutter. It's a 3/8 inch, four flute
with a corner radius on it. All the tooling, and stuff that we used in this
product are from Harvey tool. I've been using their tooling for about ten years,
and it's just been it's been great. It's always worked well. The company has been
really good to work with, and when we had to get some small tooling and everything
to make part like this, I definitely called Harvey right away, and we worked
out a, you know, we worked out what tools and stuff would work well. They actually
put me in touch with their applications engineer, and he helped me cook up some
recipes and get good starting points for all their tooling. So as you can see here,
this is on the back side of the plate, and right here, you'll notice that the
part actually moves, and we get some extra chatter. So what happened was the
cast surface finish on the plate allowed the coolant to steep in there, and then
the tape failed. So the part actually came off the fixture a little bit.
luckily it didn't look completely let go. It just vibrated for us so we were
able to, you know, remove the part, and then, as you can see, we just flipped it
over, put it in the vices and machined it flat so that we were able to save the
part, and just go ahead, and finish it. So we're working through this here. We're
cutting a series of pockets in the back. Just kind of remove some weight, and make it look
nice. But on this 3/8th's we got everything dialed in, and running pretty well.
Again, it was 350 surface footage. Programmed it at a 2 thou and 8/10th's chip load, which worked
out to right around 40 inches a minute. My depth of cut was 3/8th's of an inch,
with a forty thousand step-over. when we're ramping into these foggers
we're at a two degree ramp when we did the backside. This was a little bit
aggressive just due to the chip clearing problems. We did really have to manage
the, and the nozzle, and the quantity of
coolant coming out of it, just to make sure that we didn't have chip buildup.
Grade 2 titanium is very soft. It's about a 80 to a 90 hardness on the Bernal
scale. You know, in comparison something like 6 AL, which is a real common alloy
people are used to will be, you know 350 on the Bernal scale. So it's it's a very
soft, very gummy material. So it's a challenge to clear chips with it. So we
kind of tweaked it up, and stuff as we went, but it's one of the big challenges
that we faced with this project, was the just the material itself being really
gummy. But as you can see, we were able to rough out the pockets. Everything cut
real nice once we got our recipes dialed in. So once we got the parts' pockets
roughed out. We came back with the same cutter and we finished the top surface,
and the bottom of the pockets. When finishing the pockets I did leave
material on the wall, so I have a separate finished pass that comes back,
and cleans the walls up. I do this to keep a consistent cutter load, and it
helps improve surface finish. So it's just something that we've kind of always
done, pretty much cut the entire back side of this part with the same tool. So
we use a 3/8 on all of it, and then we came back with a real small little
corner rounding too. When we designed this, I started adding fillets, and stuff,
just to kind of deburr the part, but I didn't want to change the aesthetic of
the part, and we started putting in a 30,000's corner break on everything. It
just it really changed the appearance of the part. So Harvey Tool actually offers
a 5,000 thousand's corner rounding tool,that has a forty six thousand's diameter
tip on it. So when we flip the part over and cut the logo side of this plate
we're able to get in to all the little detail with this tool. So it's pretty
nice. Pretty cool little tool to be able to use. Definitely the first time I've
ever had to use this small of a corner rounding tool but you know it was
actually really easy to program, and real easy to use, and it just broke the edge
enough that you didn't feel the burr, but aesthetically it still left everything
looking really nice. So you see we got op one, the first side all wrapped up, and we
flip this thing over and go ahead and wrap off the logo. So we use a handful
different tools on this I started with the 3/8 and worked my way down to a
50,000 sty ammeter the pocket on this side of the part is 225,000 steep we
just took everything at full depth the cut so the three-eighths was cut into 25
deep and so was that little 50 thousandths I was really impressed that
little 50,000 oh that's all five times diameter on depth of cut so
once we get up to that footage here it was I was really impressed with that
really happy all that tool ran but we ran this three it's two of the same
speeds and feeds we did change the ramp angle on everything to one and a half
degrees just to help with chip management and keep it the tools from
loading up when we were ramping into the part once we're done with three-eighths
we came back with a little 3/16 cutter and we ran this at the same surface
footage and everything so we're at 350 surface footage we program this at one
thousand three tends to float for two and this was also a four flew cutter and
as you can see I lit one up we had that chip management issue that I mentioned
where we were healing into the hole and we weren't able to clear the chips
effectively so as you can see that cutter got nice and hot and turned red
my team is one of those materials that likes coolant and then more coolant I
actually extended the tool I'll hold a little more to get better access for the
coolants and the flushing to just fix that problem and once we had those
little issues resolved we were able to cut the rest of the part and everything
without any problems so once we wrapped up with the 3/16 cutter we came back
with an eighth inch just to clean out the corners and put a little bit more
detail in we ran the same surface footage as we did before which is 350
surface footage we ran this at a fountain 3/10 chip load this is also a
for food cutter and our depth of cut 225,000 step-over was about 37 and
thousandths of an inch and everything just ran real nice honestly we have
another one these plates to make and I'm probably gonna turn up some speeds and
feeds on that just to see how it runs and see how what we can actually get out
of these tools so stay tuned for that video we'll definitely cut this again
and lean on these tools a little bit more to see what we can get out of them
but overall I mean I was very happy with it we ran into real minimal problems the
recommendations we got from Harvey tool were excellent and everything just
worked now once we wrapped up with that ninety two thousand seven mil we got to
go down to that little guy the 50,000th this tools honestly just kept making me
smile and laugh the whole time I was using it I've never ran a cutter that
small at that kind of depth of cut before so it was definitely a fun
experience to be able to work through it was much easier than I expected the
recommendations again that I got from Harvey
were excellent and we put it in at their numbers and they just worked so in that
cutter we actually ran it we went pulled app so when 225 2 % step over which
ended up being a one thousandth of an inch step over as you can see in the
footage here it's made chips that cut really nice one of the big things when
you're cutting titanium is you can't be scared of it you have to take a chip the
material is a little it's resistant to being machined when you're cutting it so
you have to get in you have to take a bite otherwise you'll end up work
hardening and wearing out your tools so you can see this little 50,000 son mil
had a decent amount of work to do and it just did very efficiently removed all
that material I was very happy with it we did have to do some full slobbing
with it to get the detail through the center of the t logo so when we did the
slotting and everything we had to change our deficit cut so we came in and we did
the slotting here we did a 30% of tool diameter for our stuff done and then we
ran it at about a 10th and a half per tooth chip load on that as you can see
in the footage here it just cut put the numbers in and then it just ran
everything ran nice it was forming good chips we were able to keep the chips and
the you know in a good state so we didn't run into any recutting issues or
anything like that I was pretty excited about this it was fun taking a cutter at
five times diameter is I find very fun so there's definitely a fun project and
a fun part of it for us and once we finished it all up we used 90,000
Sentinal to finish the floors I wanted to get the tool fast to lay out and kind
of just follow the tormach logo on the name and stuff around to kind of give it
that offset pattern and then we came back with a 50,000 cyber and
did all the wall finishing with that is to get a nice clean consistent surface
finish on the whole thing no once we wrapped up with this guy we came back
with that little 5000 corner rounding tool again just to break all the edges
and just to deburr the part so there it is all wrapped up all clean really happy
with the way it turned out excited to have been able to work on this project
and just do it it was fun so thanks for watching hope you guys enjoyed this
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