Pushing DIY CNC to the LIMITS Milling an Aluminum Star

All the cutting tools are from Aliexpress, very cheap.

Material Removal Rate 80 cm3/min, this is the maximum i can achieve with this 1.8 kW spindle . Probably more is possible with a 6 mm mill.

Regarding the surface finish i'm very satisfied, not super good but very good like a Carbonara pasta with cruncy guanciale.

#cnc #diycnc #milling

00:00 Surface finish with face mill
00:54 Roughing
2:20 Flat area and side finishing
4:04 Chamfer
4:30 Final result

[CATANOVA]

I went beyond the limits and watched it at 2X speed. It was more cool 👍

[PiefacePete]

That was unexpected!... thanks for your honesty. 😊
Looking forward to more. (I mean more videos about your mill, not more crashes!)
Liked & Subscribed.

[ttgtomr]

That's a pretty aggressive cut for one of those 24k spindles. Nicely done. You'd do well to get some coolant. Chip evacuation is pretty important

[DrTimmay]

Hah, I know that pucker factor when the work offsets are wrong! FYI assuming you're cutting 6061 a bright/uncoated finish is probably going to give better results vs a diamond coating (assuming it's not PCD). The vapor deposition gives the cutting edge a slight roundness; Harveyperformance has a great article on it titled "shining a light on diamond end mills" (can't link in YT comments or I would!).

[alessio]

wow, have you done some video on the steel?

[geekoid]

What a nice mill !
For the next time, just know that you confused ae and ap 😉

[johnharding]

Nice job, I'm doing similar. Your surface speed on Op1 is a bit too high though, around 603, you should be between 250 and 450 really for roughing aluminium with this style of cutter. From my calculations your op is drawing around 0.91kW. Seems to work pretty well but the spindle is bogging down a bit, the max torque of your spindle is probably lower down in the speed range so I would try figure out where it is and to optimise for that. Try increasing the chipload to something like 0.08mm/tooth and reducing the Vc (surface speed) you should be able to achieve very similar MRR whilst moving the spindle speed down to say, 18000rpm, where it has likely a lot more torque (I calculate 83cm3 MRR with these changes so you don't loose out, really. Where exactly your spindle has its greatest torque is not clear without the spec sheet but it is almost certainly not at full speed) Manufacturer should have a chart. A 6mm cutter with similar settings, and 0.07mm/tooth, should get you to around 63cm3/min with 0.72kW @20krpm. YG1 roughers are similar closer to 0.17mm/tooth but you'd need a bit more horsepower for that. A 6mm YG1 does 117cm3/min but needs 1.34kW.

So an example would be (Vc 464, Fz 0.08mm/tooth, RPM 18500, Feed 4440, DOC 10, WOC 1.8 (23%) - MRR 80 to 83cm3/min (ish) - Power 0.91kW

[julianweiser]

Nice work! I think you switched Ae and Ap, is that correct?

[amrsvn-ufjk]

How much NM(newton force) / Kw of a spindle power as minimum required for steel milling process ? please accurate as possible

[shiznak]

Great work :) Did you try the same roughing operation with the finishing tool. Is there more load on the spindle or less?

[priestgaming]

Is there any vacancy in this company ❤

[brettturnage]

Put me to shame with the speed of that second procedure. I’ve got to go play with my speeds and feeds.

[Nunak]

Roughing should be described as ae 2 mm and ap 10 mm or am I mistaken?
How much ae you took on side finishing? 0, 3 mm?

[mrjackdavies]

Do you have a link to the 20mm face mill? Thanks!

[Lucas_sGarage]

Where did you buy the surfacing tool ?

[SquidHunting]

How much did this machine end up costing to make?

[mizarstifmeister]

Where did you get that spindle? also the run time is impresive, mine would have taken something like 3 hours to do that lol

[ArtutMarkov]

Эх... Коварную сталь бы показали как обрабатывает или нержавейку какую.

[dolfstromer]

Much more rpm, optimal 15-16 thousands

[testboga]

The CAM on this part was mediocre. Too much variable chipload, way too slow.