Thanks Stefan!

Yes I agree but in this case I have to machine to the drawings dimensions. The tolerance of the pockets isn’t real close. +-.010 but the corner radiuses could probably larger. But I don’t know. Thanks!

@@EdgePrecision I meant, in general, designers should put thought into giving you as much leeway as possible. This video is a great lesson to show why it matters. They may have done what they could on this part, who knows.

As one that have machined stuff like this I couldn't agree more. Good communication between designer/engineer and production is essential. Everyone benefits when the right tolerances and requirements can be set! (Thankfully I've managed to avoid copper, give me inconel any day!)

@@sharg0 Привет! Подскажи пожалуйста какими фрезами вы обрабатываете Inconel?

required viewing fir the designer - I agree. I also think that the extra cost for the needed tooling modifications should be deducted from the engineer/designer's pay along with an explanation. That would send the message home to the inexperienced designer.

We have done job before. So it is possible but you are correct it is difficult. But the money is good, no make that very good. So it will be worth it.

@@EdgePrecision well there you have it. You mentioned it was a familiar job so not so much new engineering. If it pays well enough to satisfy you, that's all that really matters. Thanks for sharing.

really like the tap extensions. very clever. i've never made one like that....yet.

As I said in the video. I'm not sure what is going on. But when I have milled pure copper this is what happens to the tool. Lets take a un-coated carbide endmill. It literally dulls the tool. There doesn't appear to be any (or very little) buildup of material on the flutes. Now carbide really isn't a solid material. It's what is known as a sintered material. Its made of compressed powder bound together with a binder then sintered at a high temperature to form the material we know as carbide. I think what is going on with copper and a carbide tool is this. The cut shaving flowing over the cutting edge of the tool is, at a molecular level welding to the binding material and dragging the carbide off the tool. This has the effect of eroding the cutting edge. So keeping everything cool and lubricated helps with this. Now a special coolant may indeed help here. But to change 300 gallons of coolant for one job. Not really feasible for me. Now a special coating again may indeed help here. But I looked into that and so far I could not find one specifically advertised for copper. But in any case this would be a very special, and probably very expensive/hard to obtain option. It is a less expensive and faster option to just replace standard easily available tooling as it wears out.

@@EdgePrecision Yeah choosing the "right" cutting fluid is difficult when the materials change a lot. But what sometimes helps is to adjust the concentration - your supplier should be able to advise on that (or it's time to find another supplier in my opinion). Same with coating, your tool supplier should be able to give good information (I'm spoiled with a supplier here in Sweden that even coats special ground cutters if needed).

I'm fairly sure I used paraffin as a coolant for copper?

Yes I would agree with you for your cutting conditions. With the slow speeds and manual type cutting strategies with no aggressive flood coolant. In this case the the small diameter tools I need in the pockets. I will need the rigidity of the carbide for their long projections. Except for some drills and maybe some reamers. I don't really use any HSS tooling anymore. I don't think I have but maybe a dozen (probably less) HSS endmills in my tool cabinet anymore.

Hey!

Or how about QPQ.

i reckon he used to.

Its usually easier to do small parts on a large machine then large parts on a small (really to large for that machine) machine. Especially so on this machine because the milling spindle has a high max speed of 10,000 rpm with 50 Hp but still has plenty of low end torque. The turning spindle only has a 1600 rpm max speed and 60 Hp. But even that is high enough speed to turn most small parts. Yes for the majority of machine parts this type of machine is one of the most versatile machine.

@Edge Precision thanks.

Yes in my machines I use water soluble oil for coolant. No I am not going to need to rotate the part. These are small pockets and the coolant should have no trouble in flushing out the shavings. Because of the doors on this machine can’t be opened while it is running. It makes it impossible to apply any oil to a tap. So I prefer to mill threads whenever possible. Otherwise I might have tried to use form taps. But if I was to break a tap in one of these parts it would be a costly mistake. So I feel better milling the threads.

I use the same inserts I machine with. Of course these jaws were aluminum. But on steel jaws slow down the speed and feed because the interrupted cut. A smaller depth of cut on the roughing passes would also be good.

I use the same coolant.

If you are referring to the holes I made the tap extension for. Not really. To do the circle for the 10-32 STI thread it’s like a 1/4-32 thread size. It would be very difficult. It would have to be a custom tool as well. Probably not impossible but for two holes I think tapping is the way to go.

@@EdgePrecision Thanks for the reply

Yes thanks for the explanation. I was wondering about this.

This kind of depends on the Heli-Ciol insert going into the hole. Heli-Coil has data on this you can get on the web if you do a search. But on this drawing they specify a thread depth.

I don’t know of anything. I think Titan made some web page where you could post your capabilities and possibly get work. You would have to do some research on his web page. titansofcnc.com/

Xometry is a company that does that.

No I don’t. But there are sometimes people that work at these places that watch my videos.

The software I pretty much exclusively use is Esprit TNG for the Mazak.

@@EdgePrecision no I know that but for simple 2d machining which 3axis Milling operation do you usually use? solid mill free form ? or variable Z roughing? or do you use solid mill MOLD even if it's not 4 axis or 5 axis?

I use the same software for everything.

@@EdgePrecision the features ? of the software what do you use for milling let's go INSIDE THE ESPRIT

Maybe I’m not understanding what you are asking. The Mazak Integrex does both turning and milling. In fact I use this software (an older version) to program for my horizontal mill. I would use the same version but I need a proper simulation model and post to do that.

I don't really know. I think because of the material and the milling it is used for a heat sink for electrical parts that are mounted on it.