Technical Machining Strategy Part 2 - strategy milling

2024-09-23 11:41:01

A plasma cutter is a useful cutting tool that can make quick work out of any metal, including stainless. For thinner material, a plasma cutter may be overkill. But, for thick pieces of stainless, it’s your best option.

Once you’ve finished cutting, you’re going to be left with a pretty nasty edge along any of the sides you cut. To truly finish the job, use a file or deburrer to remove the rough edge from your material.

Millingspeeds and feeds Chart

This chip thickness or feed per tooth, along with the number of teeth in the cutter, form the basis for determining the rate of feed.

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Tablefeedformula

First, you’ll need to prepare the plasma cutter. Connect the plasma cutter to your air compressor and turn on the air. Next, set the current for the plasma cutter. The thicker the metal, the higher you’ll set the current. For 18-20-gauge sheet, set the current around 25. Attach the ground clamp to the edge of your material.

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The feed (milling machine feed) can be defined as the distance in inches per minute that the work moves into the cutter.

Feedper tooth formula

A circular saw can come in handy for cutting through pieces of steel too thick for tin snips or power shears. The most important thing to remember is that you’ll need a proper metal cutting blade.

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Feed per tooth, is the amount of material that should be removed by each tooth of the cutter as it revolves and advances into the work.

The hardness of the cutting tool material will also have a great deal to do with the recommended cutting speed. The harder the drill, the faster the cutting speed. The softer the drill, the slower the recommended cutting speed (See Figure 2).

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Drilling machines that have power feeds are designed to advance the drill a given amount for each revolution of the spindle. If we set the machine to feed at .006” the machine will feed .006” for every revolution of the spindle. This is expressed as (IPR) inches per revolution

Tap guides are an integral part in making a usable and straight thread. When using the lathe or the mill, the tap is already straight and centered. When manually aligning a tap, be careful, as a 90° tap guide is much more accurate than the human eye.

Stainless steel is one of the most widely used materials in the world thanks to its strength, durability and corrosion resistance. Considering how strong and durable it is, it’s easy to feel a bit overwhelmed if you find yourself needing to learn how to cut stainless steel.

Use your tape measure to get an accurate measurement for the area you need to cut. Use your marker to mark off where you need to cut. If you’re going to be cutting a straight line, use a ruler or square to get a perfectly straight line.

If you’re working with thin steel, a pair of tin snips will make quick work of the job. Use the tin snips as you would a pair of scissors and slowly work your way through the material, making sure not to cut yourself on the edge you’ve created.

Before you begin cutting, make sure you’re taking proper safety precautions. Whether you’re using a saw, grinder, or plasma cutter to cut, you’ll need to wear safety goggles (or a full face shield) and heavy-duty gloves. Wearing long sleeves and pants will also help prevent you from getting any metal splinters.

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Learning how to cut stainless steel is easier than it appears at first glance. Depending on the material you’re using, you’ll be able to cut it using either tin snips, power shears, a circular saw, angle grinder or plasma torch.

Millingformulas PDF

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On the milling machines we have here at LBCC, the feed is independent of the spindle speed. This is a good arrangement and it permits faster feeds for larger, slowly rotating cutters.

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CNCfeed rateformula

Regardless of how you’ll be cutting the metal, you’ll need to prepare your workspace. A nice sturdy workbench or saw horses will be necessary for this project.

Now, you’re ready to begin cutting. Turn the machine on and bring the handle of the torch close to your work surface. Depress the trigger, and you’re ready to begin cutting. Move slowly and deliberately, and do your best to keep a steady hand as you trace your line.

Cutting speed formula

If you’re cutting through thin stainless sheets, tin snips are your best option. Thicker sheets will require power shears, a circular saw or an angle grinder. You can also use a circular saw for stainless tubing. For really heavy duty steel, a plasma cutter is your best option.

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Stainless steel comes in many different forms from sheets to bars to tubes and everything in between. Most often, the thickness of the metal is referred to by gauge. Depending on how thick the steel you’re working with is, you’re going to need one of these three tools:

Feed rateformula formilling

Pecking helps ensure that bits don’t overheat and break when using them to drill or tap. Peck drilling involves drilling partway through a part, then retracting it to remove chips, simultaneously allowing the piece to cool. Rotating the handle a full turn then back a half turn is common practice. Whenever the bit or tap is backed out, remove as many chips as possible and add oil to the surface between the drill or tap and the workpiece.

Always make sure you’re wearing safety gear. Allow the tool to reach full RPM before beginning your cut and slowly work your way through the metal.

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Fortunately, there are a few different methods that can help you make quick work of the job, and we’re going to cover each of them below.

If you’re going to be using a saw, grinder, or plasma cutter, it’s best to work outside. Otherwise, make sure you remove anything flammable from the area, as sparks are going to be flying as you cut.

Power shears work a lot like the tin snips, except they have a motor. These shears will chomp out a thin strip of metal from the middle of the cut. To cut stainless with power shears, place the steel into the jaws of the power shears, squeeze the trigger, and slowly work your way through the material until you’ve completed your cut.

Feed rateformula for turning

Feeds for end mills used in vertical milling machines range from .001 to .002 in. feed per tooth for very small diameter cutters on steel work material to .010 in. feed per tooth for large cutters in aluminum workpieces. Since the cutting speed for mild steel is 90, the RPM for a 3/8” high-speed, two flute end mill is

Once you’re prepared, turn the saw on and allow it to reach full RPM before you begin cutting. Then, lower the saw to the surface and allow the saw to slowly work through the material until you’ve completed your cut.

When drilling and tapping, it is crucial to use oil. It keeps the bits from squealing, makes the cut smoother, cleans out the chips, and keeps the drill and stock from overheating.

Once the SFM for a given material and tool is determined, the spindle can be calculated since this value is dependent on cutting speed and tool diameter.

Cutting speed is defined as the speed at the outside edge of the tool as it is cutting. This is also known as surface speed. Surface speed, surface footage, and surface area are all directly related. If two tools of different sizes are turning at the same revolutions per minute (RPM), the larger tool has a greater surface speed. Surface speed is measured in surface feet per minute (SFM). All cutting tools work on the surface footage principle. Cutting speeds depend primarily on the kind of material you are cutting and the kind of cutting tool you are using. The hardness of the work material has a great deal to do with the recommended cutting speed. The harder the work material, the slower the cutting speed. The softer the work material, the faster the recommended cutting speed (See Figure 1).

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As the work advances into the cutter, each tooth of the cutter advances into the work an equal amount producing chips of equal thickness.