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Got one finished today, should be close to the final design... damn chatter is STILL there, even after dropping feed and speed...
Looks like I'm swapping everything over to conventional from climb...



The bearing bores are .0005" over-sized for a nice slip fit.

Wow, that looks amazing. Hope I'm one of the lucky ones to be amongst the first to get one!!!

It's not easy to get a glossy finish on a milled surface

Perhaps you could drop them in a tumbler with pumice powder and ceramic pellets
Do you have access to that ?


Morten

I've got walnut shells in a vibratory right now, mainly for knocking off the small burrs.

Usually I can get away with 12K on the spindle and 24IPM feed for 1/8" carbide, but I'm thinking I'll have to halve that due to the resonance issues with. I'll also be switching the entire shebang over to conventional tomorrow, so we'll see...

I've got 2 that are good except for minor cosmetic crud (one has a fat-finger special .02 chamfer instead of a .01 chamfer, both have chatter...), so they'll be going out to people who can get me some "this needs to be tweaked".

So far it looks like treehugger is getting one of em, and I plan on punching out at least 2 more.
Then it's a small break for me to get some other projects completed while people destroy, er test, them.

On the hard-numbers side of things, how many should I make? 30? 60? I'll count up the individual responses from this thread when I have some more time.
The Delrin ones will have to wait till after the Al ones are made, since right now the price of oil has cause Delrin to skyrocket... it's now over2X the cost of aluminum!

There's like 30 people reading this going ...Eh what is "12K on the spindle and 24IPM feed for 1/8" carbide" ???

I love it when you talk shop ...lol


Morten
Ps
That 1/8" Endmill, does it have deep 2 or 4 flutes and a sharp cutting edge ?
it it coated ?

This is looking really nice. I would be interested in one too. (I can't remember if I already mentioned that I would want one earlier in this thread. Stupid memory. )

2 flute, non-coated, relieved. I'm looking for a 3 flute in the catalog as well, possibly TINI coated with a larger shank so I can put it in a solid holder instead of a collet.

Walt
That might do the trick

300D50 wrote:

looks like you could unwrap it ,and find some exotic chocolate inside

I'm mostly set on a Niagara C330 TINI coated 3 flute. There's also the Precision Twist E3603G 60 deg, but it's 5/8" flute length, which might counteract the entire reason for going 3 flute to begin with. Then again, I catch myself doing blind bore operations up to the full depth with the 2 flute cheapies I'm using now... wouldn't want to snap a $30 1/8" endmill...

I'm also going to pick up a 5/16 3 flute from whichever family I decide to go with.

Decisions...

The Niagara Cutter C330 works fast in Alloy and it's C1 to C4 range, and a great combo of strength and toughness.

However
the Precision Twist E3603G is 3 times the cost and it can be a bit more brittle and must be used with rigid toolholding
but the Titanium nitride coating does allow for a higher ipm

Both use “End Teeth” making them ideal for Slotting and Cavity milling

I would choose the C330, but Don't listen to me


Morten

IDK, you seem to have a pretty good handle on tooling info!

Went with the C330, I'm partially brand-loyal to Niagara after using one of their 1" 5 flute HSS hog mills.

It should be in by next week, so we'll see.

Sending one sample case out to treehugger so he can torture it in his truck, then waiting for the 3 flute endmill to make it's way through the mail before running any more. I can't see making more right now if the chatter continually stays...

I still have the one that's got an oversize chamfer (and is missing the chamfers on the bearing bores), so if someone else wants to mess with one they can. it's not perfect, but it's usable.

Now to get back to working on this Mercedes flywheel I've been doing odds-n-ends with since march...

Another WOW! thread--

please count me in for a 2.25 case (& a 2.60 case- if & when they are made)

Looks amazing walt! If ya want, just make everything in aluminum on that gold pan so everything will match the transmission...lol.