Shapeoko Feeds & Speeds and Machining Tips!

Introduction to Fusion 360 Adaptive Clearing with Desktop Machines

In this section, Vince introduces himself and his background in CNC machining. He also gives an overview of what will be covered in the video.

Background and Overview

• Vince introduces himself as a member of Saunders Machine Works.

• Vince explains that he will be discussing Fusion 360 Adaptive Clearing with desktop machines.

• Vince shares that his first CNC machine was a Shapeoko, which he used to push the limits of what it could cut.

• Vince briefly discusses one of his favorite parts, a sheet metal press die, which couldn't be machined without Fusion 360 Adaptive Clearing.

Flute Count and Chip Load

In this section, Vince discusses flute count and chip load for end mills used in desktop machines.

Flute Count Matters

• Vince explains that all end mills used are name brand such as Amana, Datron, Helical Lakeshore Carbide and Destiny.

• The more flutes an end mill has, the faster you need to feed it for the same RPM to maintain the same chip load.

Chip Load Explained

• Chip load is defined as the amount per tooth per revolution that's cut.

• For micro tooling (16th inch or smaller), run manufacturer's recommendations because power and rigidity isn't a problem at that point.

Single Flutes

• Vince recommends using a minimum chip load of 1 thou for eighth inch, quarter inch and three-eighths inch end mills.

• Single flutes are great for cutting dry as they are almost uncloggable.

• If you're going to run two or three flutes, it's recommended to have at least an air blast or some type of lubrication.

High vs Low Axial Depths of Cut

In this section, Vince discusses the differences between high and low axial depths of cut.

High Axial Depth of Cut

• A high axial depth of cut is when the tool is taking a large bite out of the material.

• The benefits include faster cycle times and less wear on the tool.

Low Axial Depth of Cut

• A low axial depth of cut is when the tool takes a smaller bite out of the material.

• The benefits include better surface finish and less deflection in thin parts.

Test Cuts with Different Depths

In this section, Vince demonstrates test cuts with different depths to show how they affect machining results.

Test Cuts

• Vince performs test cuts with both high and low axial depths of cut to show their differences and benefits.

• He explains that he uses Fusion 360 Adaptive Clearing for all his test cuts because it's reliable, efficient and repeatable.

Basic Machine Setup

In this section, Vince goes over basic machine setup for desktop machines.

Router and Tooling

• Vince discusses the importance of having a good router and tooling for desktop machines.

• He recommends using a Makita RT0701C router with a 1/8 inch collet for best results.

Tips and Tricks

• Vince shares some tips and tricks he's learned along the way, such as using a vacuum to clear chips during cutting.

• He also recommends using a fixture plate or mod vises, a probe, or a tool length offset sensor to improve accuracy.

Conclusion

In this section, Vince concludes the video by summarizing what was covered.

Recap

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Choosing the Right End Mill

In this section, the speaker discusses why they chose a specific end mill for their project and how it is designed for machines with higher RPM ranges.

Features of Datron End Mill

• Designed for machines with higher RPM ranges than desktop machines.

• Features a wiper flat on the bottom that allows for a good floor finish compared to most single flutes.

• Ideal for removing a lot of metal and can be run at 25 to 30,000 RPM without any issues.

Setup Details

• Using white steel core belts which are stiffer but have a limited lifespan of six months to one year.

• Running a Saunders Machine Works fixture plate with stiffener rails and two sets of mod vises due to overhang concerns.

• Tramming in the fixed side of mod vises using an aluminum fixture plate and bit zero led to ensure contact is made within about a thou.

Spindle and Router Details

In this section, the speaker talks about the spindle they will be using on their machine, its features, and how it has been converted from battery-powered to DC power supply usage.

Makita Router Details

• Using Makita router model XTR01Z which has been converted from battery-powered to DC power supply usage.

• The stock speed controller has been converted to VESC which gives complete control over the Makita router's power output while seeing real-time data and letting the user log everything for a view after the cut.

• The router is over-volted to 27 volts, and the RPM range is 2000 to 38,000 RPM.

Adaptive Clearing vs Traditional Pocketing

In this section, the speaker explains why adaptive clearing is an efficient roughing strategy compared to traditional pocketing.

Adaptive Clearing Features

• Constant cutting load by keeping its step over very controlled called optimal load which eliminates spikes in tool engagement and allows running much more aggressively.

• Gives the option of running much higher axial depths of cut compared to traditional pocketing tool paths with the same step over as adaptive.

Test Cuts

In this section, the speaker creates a sketch for test cuts and extrudes it before creating slots for adaptive clearing.

Sketch Creation

• Creates a center rectangle that is four by six and a half inches and extrudes it inch and a half tall.

• Creates three slots using another sketch on top of the previous one with each slot being about an inch and a half wide.

• Extrudes these slots down about a quarter of an inch.

Copying Tool Paths

In this section, the speaker explains how to copy a tool path from one part to another.

Copying Tool Paths

• To copy a tool path, the speaker copies it from the original part and pastes it into the new part.

• The speaker then makes any necessary edits to the geometry and feeds and speeds.

Deep Tool Path

In this section, the speaker discusses a deep tool path.

Deep Tool Path

• The deep tool path is applied to new geometry.

• The feeds and speeds for this tool path are different than those of the shallow adaptive tool path.

• This tool path has a maximum roughing step down of 250 thou.

Third Slot Feeds and Speeds

In this section, the speaker talks about using different feeds and speeds for a third slot.

Third Slot Feeds and Speeds

• The speaker duplicates the deep depth of cut but with different parameters.

• The maximum step down for this slot is only 100 thou.

Cutting Passes

In this section, the speaker demonstrates cutting passes.

Shallow Adaptive Pass

• The first cut made is a shallow adaptive pass that performs well even with an override halfway through it.

• The chip shape produced is a nice soft little curl.

High Depth Adaptive Pass

• The next cut made is a high depth adaptive pass that cuts a little bit deeper than 1D.

• There's a certain point where you're just cutting too deep and putting too much axial force on your machine.

Introduction

The video begins with music playing in the background.

Comparison of First and Second Cuts

The speaker compares the first and second cuts on a material. The second cut is louder, has peakier tones, and shows evidence of chatter when entering and exiting the cut floor finish. Chips look nice and shiny but not sharp. Walls show some chatter, which indicates that the end mill may not last as long.

• The third cut is deeper than the first cut but has less material removal rate than the first one.

• Chips still look good in the third cut, but it's not worth it due to its low material removal rate compared to the first one.

Third Cut Analysis

The speaker analyzes the third cut on a material. It sounds better than the second cut, chips look pretty good, but there is still evidence of chatter in the cut.

• Using extra flute length may be worth it if you want to save money, but it's not necessary since shallower adaptive type strategies do not affect tool life.

Feeds and Speeds Calculation

The speaker explains how they came up with feeds and speeds for their machine using a workbook that estimates machine force tool deflection and spindle power usage. They also use Millilizer software to predict milling forces and tool deflection as a function of workpiece material and machining parameters.

• Force plots for low axial high radial vs high axial low radial cuts show that shallow cuts are better options for this tool in this material.

• Speaker applies the shallow adaptive proven cut recipe to a real part, a custom intake manifold plenum floor with raised velocity stacks. They increase spindle speed and chip load for more aggressive cutting.

CNC Machining Aluminum: Tips and Tricks

In this section, the speaker provides tips and tricks for beginners on how to check the mechanical condition of their machine before cutting aluminum.

Mechanical Condition of Machine

• Check belt tension and adjust V wheels until they don't spin by hand.

• Tram in router or spindle and perform a calibration test like a circle square diamond to ensure accuracy.

• Install a tool that you don't mind possibly destroying and start with slower RPM so feeds will be more manageable.

Work Holding

• Spend time dialing in your work holding as it is crucial for cutting aluminum.

• If you can't hold your part, you can't cut your part. A setup like an SMW fixture plate and modvice make this easy but if you have an MDF table, you might have to get more creative.

Cutting Aluminum

• Start with lower axial depths of cut and work your way up as consistent and reliable cuts are the main goal when using a CNC machine. Double-check setup, work holding, and CAM before starting the cut. Be confident and wear proper safety equipment while cutting aluminum.

Analyzing Data Log of Makita Router During Cut

In this section, the speaker analyzes the data log of the Makita router during the cut.

Power Usage Analysis

• Real-life data shows what's going on when the machine is cutting; initial helix right here from what I heard in the video spikes around 275 to 300 watts once it gets into its main adaptive cuts.

• The average power usage is around 280 watts, which is spot-on with the Millilizer's estimated 282 watts.

Finishing Tool Paths

In this section, the speaker discusses how he finished the tool paths and shows the final part.

Finishing Tool Paths

• Used scallop in a Daetron six-millimeter single flute ball end mill for semi-finish and finished tool paths.

• Reinstalled the Daetron six-millimeter four-in-one and ran an inside and outside contour to finish surfaces and free the part.

Final Part

• The finish is right off the machine without any kind of post-processing or polishing. Width is supposed to be three inches; all thin about a thou that's good enough for me especially for a belt-driven machine. Be safe guys, be smart, and happy cutting!