Video: Milling Titanium 6-4 Efficiently Without a Heavy Machine

This video of machining titanium at a fast metal removal rate shows the effect of constant-engagement-angle milling.

Videos From: 2/12/2010 Modern Machine Shop, ,
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This video demonstrates the metal removal rate in hard metal that is possible with constant-engagement-angle milling, using a tool designed specifically for this style of machining.

The material is Titanium 6Al4V. Keeping the engagement angle constant keeps the load on the tool constant—as heard in the steady sound of the cut while the tool is machining. This means the overall cycle is free mill more aggressively.
 
TrueMill CAM software from Surfware provides the steady-load tool paths. The milling tool designed to take advantage of these tool paths comes from Swift-Carb. For more detail about both, see the article under “Editor Picks” at right.
 
Here are the details of this cut:
 
Haas VF-2SS vertical machining center
Swift-Carb Ramp Mill, 0.5 inch diameter, 1 inch flute length
Nikken collet toolholder
1.00 inch depth of cut
1145 ipm feed rate
3438 rpm (450 sfm)
30.7 degree tool engagement angle
0.00342 inch chip thickness
4.025 cubic inch per minute metal removal rate
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