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Author Topic: Video of my milling process - need advice on improving efficiency  (Read 20134 times)

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Re: Video of my milling process - need advice on improving efficiency
« Reply #20 on: June 07, 2009, 11:07:58 PM »
How much does Shellac run and wheres a good place to buy?

Offline Chris.Botha

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Re: Video of my milling process - need advice on improving efficiency
« Reply #21 on: June 07, 2009, 11:25:43 PM »
http://www.stuller.com/products/product.aspx?gid=11618

try them. think you need dealer account but things being the way they are im pretty sure they would be happy to sell to you anyway.
Re: Video of my milling process - need advice on improving efficiency
« Reply #22 on: June 08, 2009, 10:53:35 PM »
Two thoughts...
what about waterjetting the blanks.
Then give them a quick cleanup pass.
Or how about using a slitting saw for the slot?

Offline Sam

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Re: Video of my milling process - need advice on improving efficiency
« Reply #23 on: June 10, 2009, 12:14:56 PM »
Looks like you've got some great responses. I suppose I might as well chime in. The first thing that I noticed, was that you drilled mounting holes for the T-nuts, so you could mount the plate to your table. The use of toe clamps would eliminate the need for that. The second thing I noticed was no coolant. If you use an oil based coolant in a mister, your feedrate would definitely improve, surface finish would improve, and tool life would improve. I can see your endmill is getting coated with aluminum. After that happens (as I'm sure your aware) it's all downhill. Coolant would remedy that. DEFINITELY get an oil-based coolant. Next thing would be to make up a jig, as everybody has stated. From reading vmax's post, I can tell he's made a few. I have to agree with his method for the most part, as I've made a few myself. I do disagree with using coated cutters for aluminum, but as they say..to each his own. I would definitely use the hole in the part to clamp it down on a plate, thus enabling you to cut all the way through the part. That would get rid of another needless (and dangerous) process. Next is the use of the tumbler. Have you thought about purchasing a sand blaster? They can be purchased relatively cheap, and you can blast hundreds of parts in the time the tumbler takes to do a few. It would also deburr the parts, and leave a nice, even, matte finish, ready to be anodized. How many can you get in the tumbler? Less than 10? You could accomplish that in 5 minutes. Anodizing does not take well to sharp edges, as I'm sure your aware. If your having a problem there, you could put a fillet around the part. It's and extra step, and that means more time, but if it solves a problem you might be having, it would be worth it. A small radius makes everything look much more professional and pleasing to the eye, anyhow.
Ed had a very good piece of advice on buying a machine. I would have to agree 100%.  You would most likely have to buy or make a phase converter, but that's not a big deal at all. If your dead-set in buying a smaller mill, take a look at Novakon. You might find something there much cheaper than 10K+. http://www.novakon.net/1.html and here is a nice one Dave has... http://www.machsupport.com/forum/index.php/topic,10313.10.html
Thanks for the video, and I wish you the best of luck!
"CONFIDENCE: it's the feeling you experience before you fully understand the situation."

Offline Dan13

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Re: Video of my milling process - need advice on improving efficiency
« Reply #24 on: June 11, 2009, 11:31:30 AM »
Hi Aaron,

Thanks for the video. Nice to see the whole process of making a part.

I have a couple of thoughts:

Somehow, no one has mentioned this - your spindle speed is 6700RPM and you're using a feedrate of merely 10in/min. With a spindle speed like this and a 1/4" 3-flute end mill, your feed should be around 25in/min. Perhaps even closer to 30in/min. If your machine can't produce that feedrate, then no point running the spindle at that speed - you're heating the tool in vain. If 10in/min is as high as your machine would go, I would lower the spindle speed to around 2500-3000 RPM.

Also, like it has been stated, the more rigid the machine is the less cutting marks are seen on the part. The sharper the tool the less the marks. Flood coolant makes a better surface finish, even spraying some coolant on the final pass will do.

Like one of the guys said, cutting one part at time from a stock just enough to hold in the vice will reduce wasted stock. I agree with the idea of using soft jaws for the second operation.

Daniel
Re: Video of my milling process - need advice on improving efficiency
« Reply #25 on: May 24, 2010, 01:59:22 PM »
I realize this is an old topic, but in case you are still reading it...
Aluminum can be worked with woodworking tools, like the router in your video. I'd cut the slot with a table saw using a larger version of your jig. Very fast.

You can also save a lot of time by editing your centering scripts to eliminate unnecessary movement at slow speed. By changing to a tooling plate you can eliminate the scripts altogether.

Consider outsourcing. Submit the part for quotes to at least 10 different machine shops, some local, some not. Shipping will be negligible on these parts in quantity.

Another alternative is to use several Taig sized machines, but I doubt you'll beat the outsourcing.

Look to eliminate processes, like deburing before tumbling. A change of media may debur, as well. Use a hold down system that incorporates the table spacing instead of your current clamping. I agree with others that you can mill the holes first, then install bolts to hold down the parts to finish milling without tabs, eliminating a lot of finish work.
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Re: Video of my milling process - need advice on improving efficiency
« Reply #26 on: May 24, 2010, 02:05:31 PM »
As an afterthought, I'd saw cut the slot first, and then mill the parts from the blank. Of course, this will mean reorienting the parts in the nest.

--


Ron Thompson Riding my '07 XL883C Sportster
On the Beautiful Florida Space Coast, right beside the Kennedy Space Center, USA

http://www.plansandprojects.com My hobby pages are here:
http://www.plansandprojects.com/My%20Machines/

Visit the castinghobby FAQ:
http://castinghobbyfaq.bareboogerhost.com/


Want to have some fun? The next time you're at McDonald's, wait until the kid has your change ready and then say "Wait, I've got the two cents."
-Ron Thompson

Offline rcaffin

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Re: Video of my milling process - need advice on improving efficiency
« Reply #27 on: July 22, 2010, 07:57:09 AM »
Seems to me that the first milling step is NOT the problem. You could do 20 - 40 at a time that way.

But there are so many individual manual finishing steps after that, for each part separately. That's where all your time is going. That's what needs fixing.

Cheers