Learning the hard way

Ngray

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So I thought I'd share my experiences for the evening, some of them good, some, well, at least lessons learned :whistle:

1) Climb milling, while necessary for going back and forth across a part numerous times efficiently, has a magical effect on the leadscrew backlash. As in, it will pull the cutter down the work in a most unexptected way. Also, starting down a climb milling pass is liable to pull the whole of the work sideways in the direction the cutter is turning. Which leads me to my next point.
2) Keep the 3/4 end mill away from the X2 for now. I had a climb milling pass that, upon contacting the work (no more than a .020 lateral X .020 deep) pulled the table sideways, and bit in an extra God-knows how much, stopping the cutter most dramatically. Which had the side effect of imparting a horrible ticking noise in the head that I can't find. Probably a broken plastic tooth INSIDE the head, I'm certain it's not above the head, checked that.

Anyway, everything still seems to work, and I suppose I need to just get a sense of how much backlash I can expect. I can plan for a .005, 010, .020, whatever, if I know it's coming, and not to climb my finish pass, but I just don't know my machine well enough yet.

Net result: Learning new things, have mystery tick in the head, and am further along in my current puzzle project than I was before.
 
Been there, done that; it was quite exciting. You're lucky it was such a large end mill, you probably would have snapped a smaller one ;)

I actually find that climbing for the finish pass gives a really nice finish, but you want to stick to about 5thousands. You may also want to tighten your gibs up a bit. It can help with the nasty side effects of climb milling if you don't get too crazy.
 
Since your gears are likely about to fail (or will eventually anyway), I heartily recommend converting to belt drive. There are kits available, or you can make your own parts if you have a lathe.
 
I will say this, you're to be recognized for handling it well and in good spirit.

If it makes you feel any better, I snapped a 1" endmill in half when I accidentally chomped into a piece the wrong way (hill climb). Just a total boo-boo on my part -and I know better. I got lucky and it did no damage because I was using the cheapo mill vise that has a rotating base and it overcame the bolt tension and just swiveled. -Scared the tar out of me though...


Ray
 
I will say this, you're to be recognized for handling it well and in good spirit.

If it makes you feel any better, I snapped a 1" endmill in half when I accidentally chomped into a piece the wrong way (hill climb). Just a total boo-boo on my part -and I know better. I got lucky and it did no damage because I was using the cheapo mill vise that has a rotating base and it overcame the bolt tension and just swiveled. -Scared the tar out of me though...


Ray

As long as I am improving, and am able to recover from errors, I have to view that as positive, and something to be happy about.

Life is way too short, and there are way too many lessons to be learned for me to allow myself any other response.
 
That's the right attitude. You're going to break tools, ruin work, swear and cry. I've been doing this only a couple years, and I can't remember the last time I broke a tool. You learn what to do, what not to do quickly. I'm a firm believer that mistakes are the greatest teacher. Heck, how do you think I got so good ;) As long as you stay safe, end mills and material are relatively cheap.
 
I will say this, you're to be recognized for handling it well and in good spirit.

If it makes you feel any better, I snapped a 1" endmill in half ....... -Scared the tar out of me though...


Ray

I did the same thing one time several years ago but with 3/4" endmill. My ticker felt that one! Bad thing was, right behind it, I broke off another one, in the same place! One thing about it the Gorton 9J mill didn't miss a beat!

Ken
 
Climb milling is cutting in the driction the mill is running The endmill pulls it along. As aposed to cutting against the rotation of the mill Witgh is the normale.
 
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