Wild youtube video of aggressive hole drilling feed rates

PaMtnBkr said:
Hey Nathan, Can you explain "feed rates"? Is that how fast you push the bit through the part? Sorry to be ignorant, just not a lot of time around a machine shop. Awesome stuff any way you look at it!
Click to expand...

Feed rate is the rate the cutting tool is fed through the work piece. It is usually programmed in inches per minute, though it is calculated by inches per tooth. So lets say I have a half inch endmill that at a 1/2 depth of cut and an 1/8" radial engagement can be fed at .004 per tooth. That cutter, in that material can be spun at a particular speed (surface feet per minute) to obtain an RPM figure. That RPM, the number of teeth on the cutter and the chip load per tooth that you're aiming for brings you to your actual feed rate. It can be as low as 2 IPM, or as much as 200 IPM. The highest programmed cutting feedrate I have programed was 1,800 IPM, though feed rates like that are unusual.
 
The "ramp mill" is nothing special. That is a coated carbide endmill, probably with a variable pitch tooth. You can get good endmills like that for high speed machining at Lake Shore Carbide. http://www.lakeshorecarbide.com/ good people.

However, there is a lot more to high speed machining than the cutter. You'll notice the cutter never dwelled in the work piece, never reversed directions in the workpiece and always eased into and out of corners. And they were using a pretty mild step over, perhaps 1/8", and pealing the material off.

A little less kickass, but I took this video in my shop on my little mill :

[video=youtube_share;x_XCCK3cbqY]http://youtu.be/x_XCCK3cbqY[/video]

I'm 1/2" deep, with 1/4" radial engagement and feeding at 105 IPM. It is aluminum under flood coolant.


If you look closely, you can see a rooster tail of chips coming out under all that spray.
 
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