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0 - CNC tools
2011 Autodesk
Lesson overview
2011 Autodesk
objectives
2011 Autodesk
Overview
Many cutting tool types/shapes/sizes.
Few types needed for most CNC
parts.
Most often used listed to right.
2011 Autodesk
Web Address
McMaster-Carr
www.mcmaster.com
www.mscdirect.com
Sandvik
www.sandvik.com
Valenite
www.valenite.com
Shapes
Sizes
Geometric configurations
Materials
Corner
Rounding
Convex
Radius
Lollipop
Concave
Radius
End Mill
Tapered
End Mill
Roughing
End Mill
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Ball Nose
End Mill
Chamfer
Mill
Carbide
Insert
Face Mill
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Flat Nose:
Bull Nose:
Ball Nose:
Chamfer
2011 Autodesk
Four flutes.
Two flutes.
Rigid.
Higher feed rates than 2 or 3 flute (see Feed Formula).
More chip clearance (room for chip to be ejected).
Three flutes.
2011 Autodesk
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Includes:
2011 Autodesk
Center drills
Countersink Drills
Drill Point Countersink
Twist Drills (Jobber Length)
Stub-Length Drill
Taps-Spiral Point (Gun Tap)
Taps-Bottoming
Reamer
Counterbore
Stub
Length
Drill
2011 Autodesk
Cent
er
Drill
Twist Drill
(Jobber
Length)
Countersi
nk
Drill
Spiral Point
Tap
(Gun Tap)
Drill Point
Countersin
k
Bottoming
Tap
Reame
r
Center drills:
Countersink drills:
2011 Autodesk
Csink tip angle = machine screw tip angle (60, 82, 100, 110, 120
degrees).
Csink body diameter > screw head diameter.
2011 Autodesk
Twist drill
Tip angle usually 118 degrees.
Long drills will wobble before piercing part surface.
2011 Autodesk
Taps
Cutting:
Form tap:
Bottoming:
Spiral Point.
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Rigid Tapping
Rigid tapping:
2011 Autodesk
Reamer
Cutting speed.
Cutting feed.
Material to remove (Stock allowance).
See Cutting Data and Best Practices, Chapter 4.
2011 Autodesk
Reamer
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Counterbore (About)
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Rotational direction
Most CNC Tools cut when rotating Clockwise (view looking down
from machine spindle).
2011 Autodesk
Chip formation
Tools cut using a shearing action.
Cutting flute produces a chip that is ejected away from part.
2011 Autodesk
Chip load
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2011 Autodesk
conventional milling
Creates excessive heat increasing tool wear.
Rakes chips across surface leaving poor finish.
Not used often on CNC (mostly on Manual mills).
2011 Autodesk
Climb milling
Reduces heat and tool wear.
Reduces horsepower used.
Better surface finish.
Use unless material requires otherwise.
2011 Autodesk
Tips
Never use a cutting tool to machine plastic that has cut any metal.
Machining metal compromises the sharp edge of the tool and will
produce poor results in plastic.
A good practice is to keep 2 sets of tools, one for plastic and the
other for metal.
High speed steel cutter work best for plastic.
Carbide cutters work best for metals.
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Setup rigidity.
Quality of CNC machine.
Capabilities of CNC machine.
Material variation.
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Feed formula
2011 Autodesk
2011 Autodesk
Calculate the cutting speed and feed for a milling operation given
the following parameters.
Parameter
Tool Diameter
NumFlutes
SFM
IPR
2011 Autodesk
Value
.500in
4
600ft/min
.005in
Solution:
a. Speed = [(SFM x 3.82) / Dia]
b. Speed (rev/min) = [(600 x 3.82) / .500]
c. Speed (rev/min) = 4584 RPM
2011 Autodesk
Where:
Speed = 4584
(rev/min)
Chip Load = .005in
NumFlutes = 4
Solution:
a. Feed = Speed x Chip Load x NumFlutes
b. Feed = 4584 x .005 x 4
c. Feed = 91 in/min
2011 Autodesk
Calculate the cutting speed and feed for a drilling operation given
the following parameters.
Parameter
Value
Tool Diameter
SFM
.201in
250ft/mi
n
.002in
IPR
2011 Autodesk
Where:
SFM = 250 (ft/min)
3.82 = Constant
Dia = .201 (#7 Drill)
Solution:
a. Speed = [(SFM x 3.82) / Dia]
b. Speed (rev/min) = [(250 x 3.82) / .201]
c. Speed (rev/min) = 4751 RPM
2011 Autodesk
Where:
Speed = 4751
(rev/min)
Chip Load = .
002in/rev
NumFlutes = 9.5
Solution:
a. Feed = Speed x Chip Load x NumFlutes
b. Feed = 4751 x .002 x 1
c. Feed = 9.5 in/min
2011 Autodesk
Calculate the cutting speed and feed for a tapping operation given
the following parameters (1/4 20 tap).
Parameter
Tool Diameter
SFM
TPI (Threads
Inch)
2011 Autodesk
Value
.25in
100ft/min
per 24
Solution:
a. Speed = [(SFM x 3.82) / Dia]
b. Speed (rev/min) = [(100 x 3.82) / .250]
c. Speed (rev/min) = 1528 RPM
2011 Autodesk
Solution:
a. Feed = Speed / TPI
b. Feed = 1528 / 24
c. Feed = 63.667 in/min
2011 Autodesk
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Aluminum
Brass
Delrin
Polycarbonate
Stainless Steel
303)
Steel (4140)
Milling
600
175
400
300
80
800
175
800
500
300
70
350
.
125-.2
5
.002
.002
.005 .
006
.001 .002 .002 .
004
.002 .002 .005 .
006
.001 .003 .006 .
008
.
.001 .002 .
0005
003
.
.0005 .001 .
0005
002
.
007
.
005
.
007
.
009
.
004
.
003
Drilling
.002
.004
.005 .
010
.
015
Reaming
.005
.007
.009 .
Aluminum
<.12
5
300
120
150
240
50
200
90
100
160
35
150
66
75
120
25
100
100
100
100
35
90
60
45
35
Brass
Delrin
Polycarbonate
Stainless
(303)
Steel
Steel (4140)
.
.5-1.
25-.5
>1.
2011 Autodesk
Troubleshooting speeds/feeds
Be methodical.
Analyze what is happening and draw on resources.
Dont make the mistake of thinking the best solution is always to
reduce cutting speeds and feeds: sometimes increasing is better.
Machinerys Handbook has detailed troubleshooting information.
2011 Autodesk