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As the demand for faster production cycles continues to grow, the ability to produce high-quality parts quickly and efficiently has become increasingly important. High-speed 3D printing has emerged as a key solution to reduce lead times and increase productivity across industries. However, like any advanced technology, it comes with its own set of challenges. In this webinar, Forward AM will explore both the opportunities and hurdles of adopting high-speed printing with a particular focus on overcoming those challenges. It’ll start by discussing the fundamentals of high-speed 3D printing and how it differs from conventional 3D printing methods. It’ll then move on to the key factors that influence successful implementation, including the impact of materials, equipment and design considerations. One of the main hurdles in high-speed 3D printing is ensuring the right balance between speed and part quality. Different materials behave differently under high-speed conditions — and not all equipment is optimized for this process. Forward AM will showcase some validated materials and equipment that are proven to perform well under these conditions. In addition, the presenters will look at real-world examples and applications where high-speed 3D printing has been successfully implemented, highlighting the collaboration between designers, engineers and manufacturers. By the end of this webinar, you'll not only have a clearer understanding of high-speed 3D printing with FFF but also the practical steps and considerations needed to make the most of this cutting-edge technology. Agenda: Introduction The power of high-speed printing Know the process The practical side

Chattering - Slow down your feed rate or increase RPM. This means there is too much lateral force against the tool and it is beginning to bend and deflect its cutting edges away from the proper cut path. Most likely you are trying to put more material into the flute per revolution than there is room for (you are basically gagging the tool by shoving too much material down its throat). When you are getting chattering and deflection you are dangerously close to breaking you tooling which can cost you money and is very dangerous. I have personally had a bit break and fly across the room passing between me and a coworker about two feet next to me and bury itself in a wall (wear your safety glasses). While I have typically only used solid carbide tooling (I was spending other peoples money on tools not my own) HSS or High Speed Steel has more flex to it and can tolerate more chatter and more force against it unlike Carbide which has superior long term sharpness but is very brittle.

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I would like to address your question by considering three important factors, the most important of which is the first one:

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The latest episode “Made in the USA” podcast explores a company that uses collaborative robots, one of the key tools helping US machine shops and other manufacturers compete with lower cost countries by automating production.

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RPM and Feed relationship If you play with the formulas enough you will notice that you can get the same Chip Load with different Feed or RPM numbers. We are still using a Single Cutting edge tool.

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Take a look inside James Engineering, a high-end CNC Deburring OEM that became a job shop when they decided to produce their own parts in-house.

Milling speeds and feeds chart pdf

Climb vs Conventional Cutting This basically means are you feeding your tool around the tool path either clockwise or counter clockwise (this has nothing to do with the direction the spindle is spinning it is alway spinning the same). Some materials benefit from Climb cutting and will provide a superior edge finish. Basically when Conventional cutting you are running the tool clockwise around your path and the tool is spinning clockwise at the same time, thus, the tool is pushing its cutting edge toward the rear of the cut path. When Climb cutting the tool is spinning clockwise but is being driven around the path counter clockwise, which means the cutting edge is driving into the material in a forward motion. There is a very simple way to determine if you need to cut Climb or Conventional. Simply cut a line running from the front of the machine to the back that is a few inches long. If the cut is cleaner on the left side of the cut then you should run the material with a Climb and if the cut is cleaner on the Right of the line then cut with a Conventional. When in doubt Conventional cutting is well…conventional.

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I have learned the hard way that tools are rarely the diameter they claim to be. A .25” endmill can easily be .245” in diameter and result in parts that are larger than expected.

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When it comes to utilizing the spindle’s power, there is a lot of headroom at the upper limits, provided it’s in short bursts. Be mindful of your time at these loads so you don’t stall out.

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I just re-read my post and I think I have flip flopped conventional and climb cutting. I need to revise it tonight. I have not setup any tooling in nearly 6 months so I need to knock the cobwebs out a little.

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This is a very well-written post! Once you get into x-carve and other home made CNC machines another variable (actually about 1,000 other variables) are introduced. Not the least of which… in fact the MOST of which is machine rigidity. These machines are not as structurally sound as commercial machines. And most, immediately after assembly require hours and hours of modification, squaring, flattening spoil boards, etc. So, most x-carve users will never really experience optimum chip loads or that beautiful “sweet spot” sound. Most will subject the first .05" of their tool to overuse, dulling that section while the rest of the razor sharp flutes remain unused. The DIY CNC world is one of aspiring to commercial standards but compromising within the context of EACH individual machine. Because they are all very, very different and have very different capabilities. Once bits 1/8" and smaller are connected to a DIY machine ANYTHING can happen. The only optimum is what your machine on THAT day, in THAT material are capable of handling.

Coordinate systems tell a CNC machine where to position the cutting tool during the program’s execution for any purpose that requires the cutting tool to move.

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At its New Product Rollout, Ingersoll showcased a number of options for high-feed machining, demonstrating the strategy’s growing footprint in the industry.

Disclaimer: Please understand that my experiences and theories are based on personal experience with large commercial CNC routers and not with the X-Carve; however, tooling interacts with the material being cut the same regardless of the machine size. I have spent the better part of a decade using CNC routes to cut flat sheet materials, mainly plastics. While I have been factory trained and have industry experience I will not claim to be an expert in the field of CNC routing (or grammar). If you don’t agree or see errors in my thinking please feel free to speak up, we are all hear to learn.

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Though most frequently used for diameter measurements, an air plug and platen can be readily configured to measure perpendicularity.

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For the corresponding chip load, although you should always check your tool supplier guidelines, I think you could use up to a 0.001 inch per tooth chip load to start. As a generic guideline, we recommend chip load relative to cutter diameter as follows:

Smaller tools are easier to spin and in my experience put less lateral force against your material allowing you to hold down you’re work piece with less force. Their cutting edge is also traveling at a slower speed than an larger tool at the same RPM (remember that the outside of a wheel is traveling faster than its hub). This reduction in speed means that a slower Feed or higher RPM is typically required than that of a larger tool. I have seen that smaller diameter cutters typically leave better edge finish along the top edge of the cut if the material is prone to chipping (think plywood, or a painted surface) as the amount of material being sliced away with each revolution is smaller.

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Multi edge tooling is good for slower spindles as it allows the machine to act as if it has a much faster spindle and in relation allows for faster feeds and quicker job times. Think of cutting aluminum on a mill that has a 10,000 RPM max spindle, if you put in a three edge tool you have basically increased RPM to 30,000 as you are taking three cuts per revolution.

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If you are cutting a square that is 10"x10" your CAM software will generate an offset tool path that places the tool outside of the 10"x10" part. This is done so that the kerf of the cut (the material removed by the tool) is outside of your part. If you tell your CAM software that your tool is .250" in diameter it will place the centerline of the square tool path .125" outside of the part (called tool offset). If you then cut this toolpath with a tool that is .245" diameter and it is riding on the same .125" offset toolpath you are now leaving .0025" extra material along your toolpath as the centerline of the tool is .125" way from your part instead of the correct .1225". Because we are cutting a closed shape and not just an open line our part is being cut on all sides which means this increase is happening on all sides. Your final part is now 10.005"x10.005".

I struggle with the speeds and feed rates for "small" ball end mills (0.03125, 0.040, 0.0625) when cutting our typical tool steels such as P-20, A2, and H13. We are limited to a maximum spindle speed of 15,000 rpm. Do you concentrate on the sfm for finish end mills of the same diameter, or do you consider that the center of the ball is going to push harder for a given feed per tooth? Then, when lace cutting, the stepover becomes my next challenge. When I do feel confident with my feed and speed, I am unsure of my stepover or depth of cut.

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Number of Cutting Edges The number of cutting edges you have is basically multiplying the RPM of the spindle. If you have one cutting edge then your tool is only slicing one chip away per revolution. If you have three cutting edges then our tool is slicing three chips away per revolution. This means if I we spun the three edge cutting tool at 1/3 the RPM as the single edge cutting tool we would get the same size chip and theoretically the same quality of cut.

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I am no professor, I have just broken a lot of bits and damaged a lot of material. Just think of me as the kid that has flunked the class so many times, I just can’t help but to finally absorb the lecture.

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Ah, I didn’t consider the outside profile. In the case of an inside profile or a pocket, this would result in under-sizing though correct?

First I want to say hello to everyone, this is my first post on this forum. I wanted to write a topic that I hope will contribute to helping people who are new to machining by providing a better understanding of how a tool works in relation to the material.

Here are the three possible ways to calculate chip load. You will need to know any two variables to solve the third (chip load, feed, and rpm). Typically you will know chip load and also know a RPM or a Feed that you wish to run out, and solve for the other.

Carbide end mill cutting parameterspdf

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Coordinate systems tell a CNC machine where to position the cutting tool during the program’s execution for any purpose that requires the cutting tool to move.

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Why is correct chip load important? It results in the three best things we as CNC operators can ask for. Longest tool life, cleanest cut, and fastest possible job time. Remember though that Chip Load recommendations are just that - recommendations. They are the best place to start and then troubleshoot to refine from there.

I have learned the hard way that tools are rarely the diameter they claim to be. A .25” endmill can easily be .245” in diameter and result in parts that are larger than expected. If you are working with something that needs to be + - .01” tolerance and you start off with a tool that is .005” different in size than what you tell your CAM software you are already halfway to having you part out of spec. So always measure you tool.

If you know Feed and RPM………Feed Rate / (RPM x # of cutting edges) = Chip Load If you know RPM and Chip load ………….RPM x # of cutting edges x chip load = Feed Rate (IPM) If you know feed and Chip Load ………Feed Rate / (# of cutting edges x chip load) = Speed (RPM)

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X-Carvers are survivalists, and innovators. Long after I angrily gave up on that pathetic 24v stock spindle, others found very clever and resourceful ways to make amazing things happen. Even in aluminum. I could not and would not have persisted to achieve their results. .01" DOC with 20 IPM feed rates? But the results speak for themselves.

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Pairing automation with air-driven motors that push cutting tool speeds up to 65,000 RPM with no duty cycle can dramatically improve throughput and improve finishing.

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A reader recently used the “Ask an Expert” feature of our Micromachining Zone to ask about realizing the correct cutting parameters when using small milling tools.

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Cutting Depth Note: This is theory based on adequate horsepower and rigidity Most tooling is typically designed to cut at least at a depth of 1 x the diameter of the tool. A 1/8” tool can get optimal heat and chip clearing by cutting at a depth of 1/8”. Tool manufactures typically post their chip load as 1 X D which means 1 x Tool Diameter. Please keep in mind that cut depth is very limited by the rigidity of the machine, if your machine is not rigid it can induce chatter which can easily break a bit (especially expensive solid carbide bits which will not flex like High Speed Steel HSS when things get sloppy)

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Thank you for sharing @RichardShannon! I am just getting started with my X-carve and this knowledge you shared about feeds and speeds probably saved me numerous broken bits and hours of frustration!

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Plunging When you are moving a tool downward in the Z axis into a material it is commonly called a Plunge Rate. Please keep in mind that while most flat endmills are designed to be able to plunge downward, they are still a poor design and inefficient when compared to say a drill bit that is only designed to move down and never side to side. All tools behave different in plunging based on their tip design. I have never used a formula (I am sure someone has one out there) for plunging but I typically start somewhere about 1/10 of my linear Feed Rate and see how that goes as a starting point. You will know if you are doing it right as you will get a nice continuous coil of material (if cutting plastic or aluminum) that is being removed from the hole. If you are going too fast you will get a horrible chattering sound and moaning sound. If you are going too slow it will burn or melt the material you are cutting into.

I am assuming that when you say you struggle with these smaller cutters, you are experiencing premature cutter wear and breakage. For small cutting tool applications, the most serious problem I see is that people assume the tool tip, and therefore each cutting tool flute, is rotating with no runout. Generally, standard tools in standard toolholders only provide for a minimum tool tip runout of 0.0005 inch. This is not generally a problem with larger tools, but is devastating for small tools, and will result in premature tool breakage and poor surface finish. People tend to respond to this by slowing down the feed rate to reduce chip load.

Determining the shape of a workpiece is required in many manufacturing processes. Keep in mind these important points to ensure that you master the process.

Basic Troubleshooting Melted/Burned material or charred endmill - Lower RPM or Increase your feed speed. You are generating too much heat in the tool as a result of not taking large enough chips of material away with each revolution. You need more material to make its way in the flute on the cutter before it gets sliced away by the cutting edge. Either moving the material into the flute faster will increase the chip size or slowing down the revolution to give more time for more material to enter the flute will decrease tool temperature. Remember you should be able to touch your tooling immediately after a cut and it should only be warm and not hot.

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In short, the best results are achieve via experimentation on your machine. As often defying conventional wisdom as seizing upon an important nugget of wisdom offered by a real pro (@RichardShannon) generous enough to share their hard earned know-how.

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Your question is one we see commonly. I would like to assure you that although 15,000 rpm will limit your capabilities, you still have a reasonable range of performance on tools down to 1 mm or so in diameter. However, I think you will find that your maximum feed rates will be limited by that speed, since the bottom line really is maintaining consistent chip load. Tools smaller than 0.03125 inch will certainly need higher rpm for effective feed rate and surface finish.

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If you are finding your parts are equally inaccurate in both the X and the Y then your tool should be the first thing measured. The kicker is you need to measure the cutting diameter not the shank. The shank will be groud to a cutting edge resulting in it being slightly smaller. To take your spindles runnout in consideration you can cut a slot in a clean cutting material and measure the width of the slot and use this as an accurate tool diameter for your CAM generated offset toolpaths.

Carbide end MillRPM chart

Chip load is simply a measurement of the amount of material that is shaved off with each pass a cutting edge of the bit. This is not some mythical number, you can literally take the chips that are being cleared out of the cut and measure their thickness with calipers and it should match your calculations. Any reputable router bit manufacturer should be able to provide the Chip Load for a specific bit in a particular category of material (i.e. “Hard Plastics” or “Hard Woods”)

End Millspeeds and feeds calculator

Great post, very informative and much appreciated. This should help out a LOT of users who are unfamiliar with cut settings.

Basic Rules of Thumb: Your tool should not be hot Your chips should not be dust, they should be slices Your tool should not sound like Adam Savages “Duck Bomb” - if it sounds bad, there is a good chance it is not cutting optimally.

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If we could slow down time and witness what happens then a spinning tool is moving linear through material we would see that the flute (the void just before the cutting edge of the tool) is where all the magic happens. This flute allows material to be pushed inside of the tool which is then immediately sliced away. This amount of material that is inside the tool to be cut away is the golden key to CNC heaven. The material cut away is called a chip, this chip is not only pushed into the flute after cutting and ejected, the chip also carries the heat of the tool out with it. Yes, the stuff that is making a mess of your shop is the same stuff that is stopping your bits from turning red hot after an hour long job. The thicker the chip that is sliced away the more heat the chip can be carried away from the bit. If you are not letting enough of a chip be created inside of the tool flute you are not removing any heat and you will burn your material and your tooling. You should be making nice uniform “C” shaped chips.

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Welcome to the forum. What a great way to start. Having a concise all together primer to feeds and speeds on this forum is a much welcome addition. Thanks!

Assuming you’re cutting an outside profile, a too-small diameter results in a too-large part. One can preview this sort of thing in a vector drawing program by off-setting paths by half the ideal diameter, then assigning a stroke equal to the actual diameter.

Differential gaging measures using two devices, which has advantages over standard, comparative measurements using a single sensing head. These include the ability to measure size without regard to position.

Standards for surface finishes and profiles are not static; they change as technology changes or new processes come along that need to be considered.

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Carbide end millspeeds and feeds calculator

Carbon fiber is a material composed of at least 92% carbon, whose structure can be crystalline, amorphous or partially crystalline.

We typically recommend a carbide with TiCN or AlTiN coatings. For hardened materials, and for these small diameter tools, we recommend you do not use 4 flute cutters. Use 2 flute cutters, since the chip removal is much more efficient from the large gullet.

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Example: We will use a single cutting edge tool that requires a .005” chip load. And we are running a spindle at 16,000 RPM.

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Carbide end mill cutting parameterscalculator

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In this episode of Made in the USA, several executives and senior staff at Hardinge give their first-person account of how they formulated the plan to shift the manufacturing of its milling and turning product lines from its Taiwan plant to its plant in Elmira, New York, the major challenges they encountered and the rewards that made it worth the effort.

Single Edge Tool ……80 IPM / (16,000 RPM x 1 Edge) = .005” Chip Load Three Edge Tool ……80 IPM / (5,333 RPM x 3 Edge) = .005” Chip Load

Single edge tooling is good for machines with faster spindles (Like a X-Carve with a trim router). You are cutting once per revolution, giving the tool time to take a larger chip out of the material.

At Mill 19, the site of the Advanced Robotics for Manufacturing Institute and Carnegie Mellon University’s Manufacturing Futures Institute, robotics data provides the foundation for AI and digital twins.

The DG modular interchangeable head milling system optimizes the interface between the cutting head and shank for greater versatility, stability and higher changeover precision.

Calculate Surface Finish. Insert radius. Feed rate (feed per tooth). Calculate.

The L.S. Starrett Co. has been manufacturing precision measurement tools in Athol, Massachusetts, since 1880. Attention to U.S. manufacturing often focuses on reshoring manufacturing from other countries, but Starrett never left. The facility in Athol employs hundreds and produces thousands of tools that remain vital for measurement in machining and other fields.

Solidcarbide end mill cutting parameters

Generally, for carbide tools at small diameters, we use the following guidelines for maximum depths of cut: ● 30-40Hrc Materials—50% radial / 10% axial ● 41-50Hrc Materials—45% radial / 6% axial ● 51-60Hrc Materials—40% radial / 5% axial

Excellent post, the only thing I can add is that if someone is using the Dewalt 611 router the available RPM range is pretty high. The lowest setting is about 16,200 RPM which is pretty fast for most multi flute tooling. So as a general rule of thumb I have found that the Delwalt works much better when the setting is kept at 3 or below. Higher settings can cause the bit to overheat.

ModuleWorks and Toolpath announce a technology partnership that intends to utilize intelligent cloud-based manufacturing solutions for machining estimation and CAM automation.

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Each tool setting technique has merit, and it depends on where you are as a shop and the type of work you do, as cost and efficiency all come into play.

Recommendations: ● If you are using collet holders, be aware that standard ER collets are not sufficient for providing runout of less than 0.010 mm. UP-style collets may get you down to 0.005 mm, but that is still too much. Look for ultra precision collet systems that have dynamic runout of 0.001 mm and below. (See this article.) ● Do not assume that the cutting flute is concentric with the shank of your tool. It is common to see flute runout of 0.010 mm or more relative to the tool shank. This is yet another issue that should be addressed, since it contributes to dynamic tool tip runout.

Tool Loading This is a topic I don’t know very much about and would like if someone with experience could chime in. This is typically measured as Cubic Inches per Minute. And has to do with the physical amount of material displaced. It is mainly calculated when milling and especially when doing aggressive high speed milling. (Not typically calculated for flat sheet cutting and mild pocketing).

Determining the shape of a workpiece is required in many manufacturing processes. Keep in mind these important points to ensure that you master the process.

Job shops are implementing automation and digitalization into workflows to eliminate set up time and increase repeatability in production.