During drilling, vertical burrs are formed. At the entrance side, these vertical burrs are small Poisson burrs. At the exit side, the vertical burrs are large Roll-over burrs.

I rough 6061T6 on the Nomad @ 20 IPM, 10K RPM using 2 flute, ZrN/TiB2 coated end mills. The Nomad cannot use 0.25" end mills effectively for metals. I don’t even suggest trying.

There’s not a lot of threads about feedrates and cutter speeds yet, but it sounds like the 8-16ips @5000-10000rpm 0.01DOC in aluminum seems to be at least working for people.

Aluminum speeds and feedscalculator

Manufacturers implement a variety of tools for measurement, including magnifying glasses, calipers and micrometers, microscopes and digital microscopes. Some shops use the “fingernail test” as keeping burrs smaller than the width of a fingernail renders them manageable and easier to remove. Burrs can also be measured with a surface roughness tester if the burrs are small enough and the distance short enough.

Changing the rotational direction can make a big impact on minimizing burr formation. Consider the optimum direction prior to machining your part. For instance, if you face mill in a counterclockwise direction, burrs tend to be larger because they form on the exit side. If you change the tool path to a clockwise direction, the resultant burrs will be smaller.

End Millspeeds and feedscalculator

Will it be a good idea to have a thread for feedrates? I think it will help a lot for people who are new to CNC. I have made mistakes and broke cutters (1/32’') when I went too fast and it seems I am going too slow now.

I’ve been cutting 6061-T6 on my Nomad 883 Pro with Lakeshore Carbide 1/8’’ two flute ZrN endmill with a feedrate of 12ipm @8000rpm and a 0.01in DOC. It is sometimes very loud (especially in some directions weirdly). So it seems like I am going too slow according to your recommendation.

Aluminum speeds and feedspdf

ZrN or TiB2 will allow modest improvements in speeds and will increase the life of the end mill. Well worth the extra expense. C3D stuff is pretty good… but one can do a fair amount better. More below.

Aluminum speeds and feedschart pdf

Burrs are formed at the entering and exiting angles of a tool on the part during processes such as face milling and drilling. The size of the burr and its direction will depend on the process.

After my test cuts and plugging in the values to a SFM and chipload calculator my next test was going to be 10krpm 20IPM so it sounds like that’s a good combination. What depth of cut do you use? Do you recommend any specific end mills?

Feeds and speeds has a solid basis in physics and mathematics. The feed rate and RPM must be coupled properly for the available spindle torque to obtain a clean and optimal result. Too slow a feed and the end mill may not be cutting anything… until a step occurs… and you get a racket.

EDIT: Oh, also do you have any recommend settings for a finishing pass? Specifically for getting the best top surface quality?

The style of a tool can affect the generation of burrs depending on the material you’re working on. For example, a flat drill may form smaller burrs than a conventional drill.

I did try 12(@10krpm), 16, and 24 IPM. For me 12 IPM was the worst. It was VERY noisy/chattery. 16 sounded pretty good and 24 was a bit loud but not too bad. They all had comparable surface finishes.

Adding in deflection to the equations ensures that secondary and tertiary effects do not create problems… and tool life is improved.

During face milling, horizontal burrs are formed. At the entrance side, these horizontal burrs are small and are known as Poisson burrs. At the exit side, these horizontal burrs are large and known as Roll-over burrs.

Measuring burrs is critical to meeting spec when instructed to “remove all burrs.” However, different manufacturers have their own standards for what measurement meets this requirement and how they inspect the result.

Me, I never use C3D numbers. I do them myself, starting with G-Wizard recommendations. I factor in deflection so my rates tend to be lower than some but I get a great finish.

It also depends on what you are asking it to do,I do a lot of thin panel work so my technique is focused towards that,I have to work around panel lift as the center of the stock is normally unfixed and can be lifted by cutter action.

for 1/16, 1/8, and 1/4 end mills it recommends 9000RPM for them all and feed rates of 13, 36, and 18 IPS respectively. the 36 IPM seems a bit fast relative to what I read people here using. Does anyone cut that fast?

Sorry I’m using the 1/8" two flute endmill that came with my Nomad 883 pro. They’re uncoated. I’m cutting 6061 (not sure if it’s -T6). I’m very willing to buy different cutters if it’ll get better results. especially faster roughing. I’m also willing to change alloy.

Keep in mind that different materials behave differently during processing. This means your burrs may behave differently. For instance, stainless steel produces “gummy” burrs, versus titanium, which is a hard material that is very machinable.

Speeds and feedscalculator

You can also control burr size by adjusting processing conditions, such as the feed rate and depth of cut. Typically, increasing the feed rate increases the burr size. Using a reduced feed rate when drilling reduces the burr size, creating secondary burrs that are easier to remove. Reducing the depth of cut when milling reduces burr size, as a greater depth of cut creates larger burrs. Finding the right balance will reduce overall production time.

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Altering the edge shape on a part can help you minimize burr formation. Acute-angled edges tend to turn out larger burrs, where obtuse-angled edges make it easier to control burrs. For example, you might try corner rounding, edge breaking or chamfering to reduce burr size.  The way a part is fixtured is also important in achieving the right angle for successful deburring. In some cases, having a part completely perpendicular or parallel to the cutting surface is absolutely critical. If a machinist rips a part quickly to save cycle time yet the part is not completely perpendicular, they may not obtain enough cutting edges, potentially leaving a larger deburring burden than necessary.

While shortening cycle time may seem to be the most important priority, focusing on the overall production time including the deburring process is critical for today’s manufacturers looking to cut costs and increase efficiency. This means looking at the deburring process with a critical eye and engineering processes that minimize the time accomplishing this step in production.  Using automated deburring solutions from Xebec can reduce your overall production time and increase quality at the same time.

Minimizing burrs before the deburring and finishing process means you’ll have more options in terms of which deburring and finishing tools you can use. A burr smaller than 0.1mm is easier to remove and can be worked by most deburring tools, such as Xebec ceramic fiber brushes automated in a CNC machine or robot. The bigger the burrs are, the fewer tool options you’ll have.

When you optimize burr size and direction, it also makes your deburring and finishing processes faster and more efficient – affecting overall run time. Additionally, it will help you better maintain your deburring tools and extend their lives.

It seems like a simple progression from one phase of manufacturing to another. But many manufacturers and machine shops miss the opportunity to improve an overall run and get more out of their tools by controlling and optimizing burr formation.

It’s impossible to avoid burrs altogether in most machining processes, but you can design the machining process such that burrs turn out smaller and more manageable. Smaller burrs can make later processes, such as deburring and finishing, faster and more efficient. Reducing burr size can also help you extend the life and efficiency of your deburring and finishing tools. Realizing these benefits helps manufacturers tackle other industry challenges.

The most common variants all machine similarly. Let’s ignore this for now. In general, one needs to know the specifics of the metal they are machining. My 6061 is 6061-T6511 (the 511 is getting super specific; not pertinent to this issue). Better to know than to not know… knowing allows for optimizations.

After my test cuts and plugging in the values to a SFM and chipload calculator my next test was going to be 10krpm 20IPM so it sounds like that’s a good combination.

Understanding precisely how burrs are formed in your specific processes will help you identify the best ways to limit burr size and control direction.

No need. 6061 is awesome. In the future, for general work, T6 is an excellent choice. T6 is very common so I wouldn’t be surprised that you have it. I would stay away from T1 until you’ve got some experience - and need it.

Aluminum speeds and feedschart

Regular maintenance of your cutting tools will reduce burr formation. Sharp tools with less wear and a clean cutting edge will produce fewer and smaller burrs during processing. Worn, dull tools will produce larger burrs. Make sure to replace old and worn cutting tools and create a regular schedule for tool maintenance.

Aluminum speeds and feedsfor milling

For some manufacturers, .05mm to 0.1 mm is an acceptable burr size for “remove all burrs.” For others, it must be smaller than .01mm. And many inspect simply by touch or sight, while manufacturers in exacting industries, such as medical and aerospace, take the time to conduct further measurements.

Specifications for a part may indicate “remove all burrs.” In these instances, burrs must be removed to avoid issues down the line. For this phase of the process, you’ll use deburring and finishing tools after processing, such as Xebec ceramic fiber brushes.

Also worth pointing out that cutter diameter is crucial to material removal and ejection which is directly linked to the cut speeds you can attain,the larger the better.

We’ve identified six potential alterations for manufacturers to consider to better control burr formation in processing and improve production.

Aluminum speeds and feedstable

Burrs cause problems both in the shop and down the line. Depending on the part being created, burrs can be consequential to:

It’s easier to remove vertical burrs. Adjust the orientation of the burr by end-milling first and face milling second. Similarly, with cross holes, generate the burr on the larger hole as it will be easier to remove the burrs inside the large hole.

If you’re in manufacturing or machining, you’re likely familiar with burrs. Burrs are protrusions of material, such as metal, resin or polymer, generated from the processes of creating a part.

All I cut is Alu,mainly T6,I use a combination of a 3mm 2flute 45 Helix cutter at 16000-17000 Rpm with a .17mm DoP with a feed of 400mm/min,Alu I find favours a thin and fast approach rather than the Ron Jeremy Deep and Slow,I finish with about 200-250 mm/min,similar to Marks approach.