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we were doing patriot missile fuel cells in alum at 10,000RPM! this was on the BIGGEST MILL IN THE STATE at karsten PING as in golf clubs. this was the proveribile poo thru a goose as far as CHIPS FLYING. sounded like a freeking machine gun going off. used helical indexable inserts on milling cutters from ISCAR
actually the helmet is NOT that big of a deal.
1st you take a CMM(coordinate measuring machine-starrett) and mark ALL "X", "Y", "Z" points, download to puter and then do yer program indicating ball mills, indexable insert mills,coolant fed mills as far as tool selection, how many passes,tolerances,DOC(depth of cut) speeds/feeds etc.
the impressive thing here is how many tools were ditched and the CYCLE TIME to produce it.
diamond coated tooling on aluminum anyday if yer machine has the HP/RPM to haul azz and the ability to remove chips once cut, as to NOT recut same chip over again.
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if there are TROUT..........there are BEARS!
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