Hi, Jason with Tormach. We've got a tooling video for you guys today.
Thanks for coming and checking it out. We're gonna talk about our Dijet
hi feed style end mill, that we can use with our modular TTS tooling.
So let's dive into this thing, and see what kind of capabilities, and how to utilize this tool.
Here it is, it's you know, it's this little, it's a half-inch diameter 3
flute high feed style end mill. So what's a high feed end mill? It's a tool that's
designed to reduce the engagement angle of the material in the cutter. So it
thins the chips out very efficiently, This reduces cutting forces and allows
us to just turn up the feed rates. They're really fun to use on this little
half-inch cutter we can run chip loads all the way up to about 15 thousands of
an inch per tooth, which is just insane. Super fun, and it does this all through
hard materials as well so you can see it's a modular style cutting head so we
can fit it on to any of our three different lengths of six millimeters so
this is an M6 holder. So we have a shorter, medium, and long. You can see this
one's currently mated up with the short holder. You know you as always
keep your tools as short as possible, and when you need the really long tool you'll see
in some of the cutting footage that we're gonna run through that we're gonna
use the long holder, and we're gonna, you know, lean on these things, and test them
in all the different scenarios. We kind of got some fun tests for you guys lined up.
I've got some one two three blocks. I've got some hardened vise jaws, both
of those are about a sixty Rockwell C. I've got some pretty hardened chromoly,
some 4140, we've got some stainless steel, we've got some mild steel. I'm just
trying to run these things through the paces, and see how they perform. So we've
got three main types of inserts available for this for this cutter. As I
mentioned, this is a high feed style cutter. It's the reason why we have
it but they also offer a traditional style insert for it where it's just
going to do shoulder milling. So that's this insert here. The naming structure
starts with a Z. So anything with a Z at the beginning, this is going to your
standard traditional shoulder milling style insert. For this kind of testing
and stuff this isn't why we have this cutter this isn't the stuff we want to
explore and test with it today, but I just wanted to let you guys know that if
you need a shoulder insert for this cutter it is available.
The other two types that we have, it really differentiates between
them between materials. So we have an insert that's for 50 Rockwell C, and up and we
have the insert that's for less than 50 Rockwell, and then there's a couple
flavors of each as we go. So we'll start with the inserts that are for the softer
material. Anything under 50 Rockwell C, these inserts are going to start with it a E.
So on this specific one we have an E0, or EOMT. So what does that mean?
The T is the chip breaker. So this inserts gonna have a little more defined chip
breaker on it. It's gonna work really well for really long tooling, for
stainless steels, gummy materials. It just reduces your cutting force. So it's good
in all those scenarios. It makes the insert a little less
durable, but it also makes it work in in a little more difficult scenarios as
well. This is kind of gonna be your general purpose insert. So if you're just
cutting 4140's, stainless steels, and stuff like that, this is kind of the
insert you're going to want to have around just as you're kind of go to insert.
The second one that we have..for the softer materials, it's going to be this EOMW.
And the W is for unfavorable conditions. So if we're gonna do interrupted cutting,
if we have scale, or heat-treat scale, or just you know, any conditions that you're
looking at your part, and like man this is gonna be really hard on tooling
you're going to want to switch to the W style. It's just gonna be a more durable
edge on the insert. As you can see we cut up a 1-2-3 block this was about the
worst scenario I could think of, as far as materials, and stuff I had laying
around the shop. This is about sixty Rockwell C, and it's interrupted cutting.
It's very hard on your tooling. So again, that's the EMOW's for your
unfavorable, or your on, you know, the harder to machine conditions. When we
get to hard materials, we have the EOHW's. So the H is for hard and then these
are all going to be that W style they don't offer that chip breaker for the
high heat for the high temperature coatings and stuff. So when we look up at
this insert, you can see that the shape, and the insert.
This thing's pretty much solid, and straight there's no chip breaker on it.
It's designed to handle that really high temperature you get from
machine hardened steel.
There are some considerations you need
to keep in mind when you're using a high feed style cutter.
These are designed to be used to exploit
chip thinning so they are designed for really light depths of
cut. These are really small inserts on this cutter.These are very small three
flute on a half-inch cutter. The maximum depth of cut you'd want to take with
this cutter would be about fifteen thousands of an inch. Realistically, when
you program this, if you want to get good tool life, not really have to worry about
the inserts failing prematurely, if you stick with that ten to twelve
thousand step to cut you just get really good tool life. They hold up well if you
overload them a little bit in corners or something they don't pop an insert. So
we just found it running into that ten to twelve thousand depths of cut, they just
last a lot longer, and then your chip load. Your chip load can be pretty
consistent from material to material on these. So again the recommended, like
where we like to see these start out, is that ten to twelve thousand per tooth.
You can push them up a little bit higher than that, but again, you start getting
into that...you're pushing the limit..you can start to see the inserts fail a
little prematurely. You can definitely run them there if your machine sounds
good and everything's running well. You know, you're not gonna hurt it, but a
good starting point is that ten to twelve thousand spur tooth. And then
surface footages, and stuff like that, these get really high on a pre-hardened
block of forty one forty, we can run surface footages up to about five
hundred on a piece of hardened steel. Which is amazingly fast. So we'll get
into this a little more specifics on each kind of material as we work through
in all the cutting. I'm excited to get this thing running, and get some more
tips flying off of it. So let's just jump into the cutting
here, and we'll work through some of the recipes. Alright so this is a one to
three block.We put this on the hardness tester and it came up to be about a 58
to 60 Rockwell. The inserts I started with were just the standard VMOT's. So
they're inserts for the softer material. I had them in the cutter. I just kind of
wanted to try it out, and see how it would work. As you can see when it's
cutting through this material, there's quite a bit of sparks. It, you know, it's
definitely the wrong insert. We did wear the inserts out in the two
passes that we took with it. Like as I mentioned, just something we wanted to
try out in case, to see what kind of tool life we would get. So here we switch
to the appropriate insert for this material. It's the EOHW, so this is for
the hard materials, you know the 50-plus Rockwell's. We're running this cutter
at about 400 surface footage, at ten thousand depth of cut in a ten thou chip. As
you can hear on this cutting, it is a pretty aggressive cut. I was trying to
find a really, you know, basically a terrible cutting scenario for this
cutter so this is a high hardness high interruption. You can hear the machine
loading and unloading as it's cutting. The video actually makes it sounds a
little worse than it does in life. It was definitely an aggressive cutting. This
program is just done in the conversational in PathPilot. So
something we just wanted to try out quick and dirty. You can see the surface
finish here, it actually looks pretty nice for a roughing tool. A lot of times
with a cutter like this, you'll get some really aggressive feed rates, which give
you a really aggressive, you know really rough surface finish, but this actually
looks pretty nice when it's finished. This is a block of forty one forty pre
hard. Those coming in about a twenty eight to thirty two Rockwell C. We're
just doing a little bit of kind of 3D profiling, roughing, on this. You can see
on the tool path here that, leaves some islands. So when I define the tool in cam
I didn't quite have the diameters and stuff set right. I just kind of decided
to leave it a little bit higher load, a little bit overloading scenario, just to
kind of see how the cutter would handle it. So not an ideal tool path but we just
left it to see how it would do you can see in some of these slow-mo Clips here
that you can actually see these chips coming off Brown and then they're kind
of half brown half blue so we know we had our surface footage dialed in pretty
well with this one we were running this at about 500
surface footage at that same tenth ow depakote and ten township load on the
ramping here on the circle in the slot we did slow down the feed rates a little
bit just to free up some horsepower and allow the machine to work this is a
hardened steel vise job that we had this is also a lot of 58 to 60 Rockwell for
this cutter with off the same inserts in so we're still running the hardened
inserts here we ran this at 400 service footage as well you can hear on
this it sounds a lot nicer than that one two or three black does it has a lot
more consistent loading on the tool without all the interruptions
you know then as I mentioned we ran this about 400 surface footage kind of your
starting point for a hardened material like this you want to be in that 3 to
400 surface footage range is a good place to start and with all these cuts
were wrists running the the fog Buster with the coolant turned off so all these
are just using any air blasted clear chips this footage here is from our a
quadcopter project that we had previously done so this was in 304
stainless so this was about 325 surface footage at ten thousand a tenth our chip
again and we roughed out two different mold halves on this we had almost three
hours of cut life on these inserts and they were you know still looking pretty
strong at the end of the cutting these were the emot so these were that the
chip breaker in hurt that is designed for those who come he stainless steels
and lower cutting forces we chose their own flood coolant on the stainless just
to help with heat management we didn't we really didn't want to heat up this
part too much and cause the work hardening to happen so we did run flood
coolant you can see it just has its own challenges you need a quite a bit of
flood coolant to flush parts out of a over an inch deep pocket and you're
making chips as fast as you are with this die jet cutter this footage here
this is just a block at 10:18 mild steel we had it some just a three inch round I
just wanted to do some aggressive ramping so this was just kind of a
little bit of play session you can see we're in the real long extended holder
here we ran this about 350 surface footage at 10,000 we did ten thousands
per revolution on the ramp angle here just to keep the cutter at that light
depth of cut but we were able to run this very fast we were running this
right around 90 inches a minute and as you can hear it sounds really nice while
it's working through this material definitely you got some chip management
concerns and troubleshooting to do here it's a couple inch deep pocket that
we're going through so just got to blow the chips out of the bottom so just
using tool fog buster nozzles for chip clearing so kind of just to
summarize what we what you guys have seen here is we cut some you know we've
got everything from mild steel some stainless steels we've got some hardened
steel some alloy hardened Steel's you know this cutter is very capable it
works throughout a wide array of different materials it performs very
well it's very efficient at removing material we'll have a link in the video
description below for specifics on what inserts are for
what materials with part numbers and everything for you guys to make it easy
thanks for watching I hope you guys enjoyed this overview video on the die
jet high feed mill as I mentioned they're super fun pick one up try it out
have fun with it feel free to check out other YouTube
videos here and subscribe to our YouTube channel here