CNC Mill Machining Videos

Tormach PCNC 1100 Series 3 Cutting Demonstration. Workpiece is Aluminum 6061-T6. Flood coolant for hole making operations/Mist coolant for roughing and finishing. Tapping fluid used for tapping operation.

List of tools used during this demonstration:

1. Center Drill
2. .325 Machine Drill
3. 1/2" Chamfer Mill
4. 3/8" - 16 Tap http://goo.gl/AnMXG
5. 17mm Index Cutter http://goo.gl/Lb4So
6. 3/8" Finish Mill
7. 1/2" Chamfer Mill
8. Fly Cutter http://goo.gl/sttMq

If you want links to the products described in this video, click on "show more" and scroll down.

In this product video, Tormach's Mike Corliss demonstrates the use on the new ER 16 and ER 20 tension compression tapping heads. He also explains the speed calibration procedure to get the best results. And finally, he shows how easy it is to use the Stop Loc measurement device is to get consistent results between parts.


ER 16 Tension Compression Tapping Head: http://goo.gl/1aIUK

ER 20 Tension Compression Tapping Head: http://goo.gl/RhW8e

Stop Loc: http://goo.gl/rMqae

The brand new Tormach Tooling System® SuperFly Cutter kit is a modern riff on an old shop standard, bringing the latest advances carbide insert technology to small CNC machines. The Superfly is a single tool that can provide both superior surface finish or increased material removal rates for spindles less than 3 hp. In our latest Fab Lab video, we give the SuperFly a workout in both aluminum and steel.

For more information on the development and use of the Tormach TTS SuperFly Cutter read TTS SuperFly Cutters: A Modern Update to an Old Shop Standard, on our blog here: http://goo.gl/wNnZG


The SuperFly Cutter can be purchased here: http://goo.gl/FQW6H

The Y-Axis Chip Flap can be Purchased here: http://goo.gl/YuDgE

The Ring Light can be purchased here: http://goo.gl/6ZEoV

The brand new Tormach Tooling System® SuperFly Cutter kit is a modern riff on an old shop standard, bringing the latest advances carbide insert technology to small CNC machines. The Superfly is a single tool that can provide both superior surface finish or increased material removal rates for spindles less than 3 hp. In our latest Fab Lab video, we give the SuperFly a workout in both aluminum and steel.

For more information on the development and use of the Tormach TTS SuperFly Cutter read TTS SuperFly Cutters: A Modern Update to an Old Shop Standard, on our blog here: http://goo.gl/wNnZG


The SuperFly Cutter can be purchased here: http://goo.gl/FQW6H

The Y-Axis Chip Flap can be Purchased here: http://goo.gl/YuDgE

The Ring Light can be purchased here: http://goo.gl/6ZEoV

The Tormach Boring Head can be found here: http://goo.gl/p87Ek

In part 2 of the basic boring head video series, we show how to set up a boring head to turn the outer diameter of a part with a CNC mill.

The Tormach Boring Head can be found here: http://goo.gl/jXOUC

This video shows the basic setup procedure for using a boring head to bore out the inner diameter of a hole with a Tormach PCNC mill or other small milling machine.

Mike Corliss, Tormach's Machinist and Technical Support Specialist, demonstrates the basic strap clamp techniques to secure parts to a table.

Please visit this page to purchase our Strap Clamp kit:http://goo.gl/bVDMP and the information page to find out more about our workholding products http://goo.gl/6yTij

Follow Tormach's blog here: http://goo.gl/ulCcn

Visit Tormach's website by clicking this link http://goo.gl/cNggJ and to visit SprutCam clikc on this link http://goo.gl/ufYIg

In part 3 of this series, Eric Andersen continues the process of reproducing a gasket for his 1983 Yamaha Scooter. In this segment he machines out the gasket using a drag knife, Mach 3 and the PCNC 1100.

Watch Part 1 here: http://www.youtube.com/watch?v=-6QxUEt5mlA
And Part 2 here: http://www.youtube.com/watch?v=X0xDbu9NRvs

Visit us at http://www.tormach.com and http://www.sprutcamamerica.com to find out more about all the tools used in the recreation of this gasket.

In part 2 of this series, Eric Andersen continues the process of reproducing a gasket for his 1983 Yamaha Scooter. In this segment he takes the scan and imports it into SprutCAM and creates the tool paths. In Part 3 he cuts the part out using a drag knife.

Part 1 can be seen here: http://www.youtube.com/watch?v=-6QxUEt5mlA

Visit us at http://www.tormach.com and http://www.sprutcamamerica.com to find out more about all the tools used in the recreation of this gasket.

In part 1 of this series, Eric Andersen takes a carburetor from his 1983 Yamaha Scooter and uses the tools offered by Tormach to make a reproduction gasket. In this segment he sets up the carburetor on an 1100 CNC and uses the CNC scanner to capture it's geometry. In Part 2 he takes the scan and imports it into SprutCAM and creates the tool paths.

Part 2 can be seen here: http://www.youtube.com/watch?v=X0xDbu9NRvs

This video demonstrates face milling with the Tormach PCNC 1100 in three different materials: 1018 Low Carbon Steel, Stainless Steel 304L, and Aluminum 6061-T6. Feeds and speeds were chosen with the help of GWizard Online Machinist's Calculator. The Face Mill is 38mm in diameter. Visit http://www.tormach.com for more information.

This video shows several CNC thread milling operations using a Tormach PCNC 1100. Thread milling is demonstrated in both steel and aluminum using a 60 degree single form V cutter.

This is an introduction to the Flash based graphical user interface.

For more information go to www.tormach.com

Task: Changing Tools on the PCNC
Materials:
1. Tormach PCNC
2. Touch Tool
3. Twist Drill
4. Face Mill
5. Small end mill
*Can use different specific tools if wish applying the same concept.
Intro: There are dozens of techniques for tool measurement on the PCNC, the easiest way to learn about these is to begin by looking in the PCNC Manual where they are all listed.
In this Instructable we will show how to measure a tool for the first (and only) time and then do tool changes on the Tormach PCNC machines.
For more information about Tormach, check our www.tormach.com.

1. What We Need
a. Before we can run the program the controller needs to know the program position. This is the distance between the tool and work surface. For this we will need 3 pieces of information, 1. Tool length, 2. Machine position, and 3. Work offset.

2. Measuring Tool Length
a. To measure the tool length we will use a small granite block and height gauge which can be placed directly on the mill. We will use the following tools for measuring in our Instructable, but you can replace them and follow along using the same system if you do not have these specific tools.
i. Touch Tool
ii. Twist Drill
iii. Face mill
iv. Small end mill
b. Open the tool table and use the height gauge to measure the touch tool. You will read two numbers and by adding them together we got 6.9565 in. By measuring this length once you can use that as the zero gauge reference for later usage. You should only need to measure each tool once.
c. Record the tool length.
d. Repeat this same process for each tool.
3. Referencing the Mill
a. Referencing the mill will give us the correct machine coordinates.
4. Set the Work Offset.
a. To do the work offset the controller needs to be using the touch tool so change to tool #1 and confirm.
b. Bring Z down until the Touch Tool is compressed in the exact position it was when it was originally measured.
c. X and Y must also be set before you can run the program.
5. A Quick Look at the Program Controls for Tool Change
a. The first command is G28 -this is the tool change position and works in machine coordinates relative to the home reference position.
b. T2 shows that the machine will make sure to use tool #2.
c. M6 will initiate a tool change— (because in our case this is a manual action the machine will stop and flash a yellow indication on the screen to change to tool #2 before you can continue.
d. G43 indicates that tool offset should be applied and H2 indicates that tool #2 is the one to use.
6. Run the Program
a. Hit cycle start and then follow the tool change prompts on the machine. The tool will go down and make a small pattern on the material and then there will be prompt to change the tool.
b. Put in Tool #3 and hit cycle start.
c. At the flashing prompt put in tool #4 and hit cycle start for the last cycle of the process.
7. Check out tormach.com for more videos and information.

http://www.tormach.com/videos/20112_Tool_Change/SimpleToolChange.tap.txt
For more information check out www.tormach.com

Tormach on the web @ http://www.tormach.com

The standard Duality Lathe has a spindle clamp and 360 degree index wheel. This allows the lathe to be used as a fixture, holding the turned piece for machining with the operator doing manual indexing. With this new option the Duality Lathe is transformed into a 4th axis by clutching in a precision drive mechanism. The drive is fully integrated into the mill CNC controller and has the same drive ratio as the conventional 4th axis, allowing both the Duality Lathe 4th axis and the 8 conventional 4th axis to be used on the mill (not at the same time).

Duality Lathe and the Duality Lathe 4th Axis Drive combination greatly extend the capability of the Tormach mill and can be used for a wide variety of small or lightweight mill/turn operations.

Tormach on the web @ http://www.tormach.com

Overview:
A 3/4" steel plate is cut to size and finished with two different end mills in the process of making an 8" chuck adaptor plate.

This video reviews a standard milling operation on low carbon steel. The task involves creating an 8" diameter circular plate from an 8.5" x 8.5" x 0.750" square plate.

Material: 1018 Steel
Cutter: Cobalt HSS rougher
1/2" 4 flute end mill
1/4" HSS 2 flute
Speed: 700 -1200 RPM
Feed: 1-4 IPM
Machine: Tormach PCNC 1100

Background:
Mild steel was used to make chuck adaptor plates. The process involved 3 operations using 1/2" roughing end mill. These were 1) cutting the circular shape from a rectangle, 2) squaring off a chamfer left behind by a face mill, and 3) finishing the outer diameter. Finally, we switch to a 1/4" end mill and put a precision cut on the pilot. Climb milling was used throughout.

Read more:
http://www.tormach.com/MfgDatabase/20105_Milling%201018_Steel.pdf

Key words:
Tormach, CNC, 1018, steel, mild steel, cobalt, HSS, high speed steel, edge milling, finishing operations, rotary table, pilot, end mill, rougher

Tormach on the web @ http://www.tormach.com

The Duality Lathe is an entirely new concept in CNC mill accessories. When used in combination with a PCNC 1100 mill, this integrated machine accessory can be operated as a CNC lathe, or combination lathe/mill. When used without the PCNC 1100 mill, the Duality Lathe becomes a conventional bench top manual lathe.

When mounted to the table of Tormach's PCNC 1100 mill, the Duality Lathe becomes a CNC lathe. Mounting the lathe is as simple as mounting a machine vise. Two cables, a power cable and a signal cable, provide integration of the mill and lathe control systems. The combined system offers CNC turning, cut-off, boring, drilling, and threading. Dedicated lathe control software includes code programming wizards and supports code programs as long as 10 million lines. The Duality Lathe includes a quick change tooling system. The Duality Lathe also includes spindle clamp and index wheel, allowing milling operations to be performed on parts while they are still mounted in the lathe chuck.

"With this new invention we're enabling our customers to leverage their investment in a CNC mill by providing CNC lathe capacities for a fraction of what it would normally cost." says Tormach CEO Greg Jackson. "The Duality Lathe is the perfect solution for entrepreneur's, researchers, inventors and educators, where shops have limited budgets and only occasional need for a CNC lathe."

OVERVIEW:
This application note covers an interesting application of the Tormach PCNC 1100 milling machine. This video has been posted by Tormach. The original author is SDM Fabricating (http://www.sdmfabricating.com) and is published here with permission of the author. For more information about Tormach CNC machinery please go to our website at http://www.tormach.com

COMMENTS from the Author (SDM Fabricating):
For very little investment you can make a tool holder and use your mill as a vertical lathe with indexable tooling. I made my tool holder in a few hours. Well worth the time. Here is the long and short of it. Work is held in the spindle, tools in the tool holder.

DRAWBACKS:
R8 spindle, anything over 1" needs a chucking lug. no center support, short overall lengths, no CAM support, you'll have to write the code yourself (or do some fancy editing). Here is a picture of the Tool holder: http://www.sdmfabricating.com/Tormach/P1000364.JPG

To make programing easier I used a different work offset for each tool. I bored the tool holder with three 3/4" bores so I could use my Tormach Tooling. The ER 20 collets will hold anything up to a 1/2". With a spot drill, a drill and a boring bar you could do just about anything. But I added an extra hole anyway. The spot drill has a place all its own.

In the following video I am making four collars for a product I sell. The material is 1018 mild steel 5/8" dia.
OP 1 Face and turn (chamfers are done here with the turning tool)
OP 2 Spot drill
OP 3 drill (Deep hole 2.3")
OP 4 ream to size (reamed to 2.1" deep)
OP 5 Cut Off

Tormach on the web @ http://www.tormach.com

Overview:
This video reviews how to use an edge finder and the difference between a mechanical edge finder and an electronic edge finder.

Material: 2" Aluminum
Cutters: Mechanical Edge Finder, Electronic Edge Finder
Speed: variable
Feed: n/a
Machine: Tormach PCNC 1100

Background:
Essentially an edge finder is a dynamic indicator of the location of a work-piece edge with reference to the center line of the spindle to which it is attached.

Fixtures & Tooling:
The mechanical edge finder in a simple device and can be purchased for as little as $10 USD. In order to operate this type of edge finder, you need to have a rotating spindle.

An electronic edge finder is a bit more complicated and will cost a little more. Its main advantage over the mechanical edge finder is that it can work in a NON-rotating spindle. It is battery operated and works by lightening up its internal LED (usually red) when the electrical circuit formed by the instrument and the machine is closed.

Motion Planning:
The edge finder is put in the rotating chuck of the milling machine and the work-piece is moved towards the edge finder.

When the work-piece and the edge finder come into contact, the rotating motion of the edge finder visibly changes.

In use, the spinning edge finder is moved into contact with the edge that you wish to locate. As the lower cylinder of the edge finder touches the edge, that lower cylinder "kicks" to the left (assuming a clockwise rotation as seen from above). When the kick is observed, the axis of the spindle and the edge of the work-piece are located 1/2 the diameter of the edge finder from each other. This is typically 0.100" but it can be different, so make sure to check.

Cutting Process & Results:
With either a mechanical or electronic edge finder, you will be able to center your work-piece accurately every
time.

Key Words:
edge finder, mechanical edge finder, electronic edge finder, wiggler, centering, machining, milling techniques, CNC, Tormach

Tormach on the web @ http://www.tormach.com

Overview:
This video reviews carbide spot drilling and HSS drilling in cast iron.

Material: 1.5" cast iron
Cutters: Carbide Spot Drill, HSS End Mill
Speed: 1000 RPM, 900 RPM
Feed: 1.7 IPM, 2 IPM
Machine: Tormach PCNC 1100

Background:
Traditional twist drill bits may tend to wander when started on an unprepared surface. Once a bit wanders offcourse it is difficult to bring it back on center. A technique called spot drilling, in which the center of a hole is started, frequently provides a starting point for the traditional twist drill.

Fixtures & Tooling:
The tool used in the first part of the movie was an insert carbide spot drill. In this case, we decided to use a spot drill to insure that the second tool we use does not wander off the drill mark. We used drill cycle G73 with a feed rate of 1.7 inches per minute.

The tool used in the second part of the movie was a traditional high speed drill bit with titanium coating(letter drill B). It was run at the slow speed of 56 surface feet per minute. This allows the bit to remain cool and last longer. We used drill cycle G73 with a feed rate of 2 inches per minute.

Cutting Process & Results:
Cast iron is a very easy material to cut, but it creates a lot of dust. It is important to have a vacuum handy to clean up the dust during the cutting process.

Application Note Link:
http://www.tormach.com/document_direct_download.html?doc_id=525

Key Words:
cast iron, spot drilling, HSS end mill, carbide spot drill, machining, milling techniques, CNC, Tormach

Tormach on the web @ http://www.tormach.com

Overview:
This video reviews cutting a 3" diameter hole into 2" High Density Polyethylene with a ½" 2 flute high speed steel cutter.

Material: 2" High Density Polyethylene
Cutters: ½" HSS 2 flute End Mill
Speed: 2500 RPM
Feed: 20 IPM
Machine: Tormach PCNC 1100

Background:
Milling is described as climb milling or conventional milling. Convention milling is when the cutting edge enters the material at the finish surface and exits on the uncut surface. Climb milling has the cutter entering the old surface and exiting at the finish surface. Climb milling provides longer tool life and better surface finish, but requires a precise machine tool with no backlash.

Fixtures & Tooling:
The work piece was clamped to the machine table using parallels between the table and the material so the cutter would not hit the table when it went thru the part. The tool used was a standard ½" 2 flute high speed steel cutter.

Motion Planning:
We started out with a 10" step per minute plunge into the HDPE. This is not the optimized tool path, indicated by the swarf build-up on the tool. If we would have used a peck drilling technique, we would have chips instead of swarf and this would result in a cleaner cut. At the end of the cut, we spiral out at an 80% cut, meaning 80% of the ½" tool diameter or 0.4". This technique is called climb milling.

Cutting Process & Results:
High Density Polyethylene is a very easy material to cut. Even without an optimized tool path, the cut was smooth and quiet. We cut the HDPE at 20" per minute. To prevent recutting, heating, and a poor finish the operator used a vacuum to pick-up chips.
http://www.tormach.com/MfgDatabase/AN20109_CircularInterpolationMilling.pdf


Keywords:
HDPE, High Density Polyethylene, HSS end mill, 2 flute end mill, climb milling, peck drilling.

Tormach on the web @ http://www.tormach.com

Overview:
Three tools are used in sequence for roughing, finish cut, and then chamfer. Run time is 12 minutes, including tool change. The part is 6061 Aluminum, 3/4" thick.

This video reviews multiple operations on
a sample aluminum part. Using three tools, a part is created from a block of aluminum using roughing, finishing, and corner finishing.

Material: 6061 Aluminum
Cutters: 3/8" cobalt 4 flute end rougher
3/8" carbide 2 flute
K-Tool insert spotting drill
Speed: 3500 to 4500 RPM
Feed: 20 to 30 IPM
Machine: Tormach PCNC 1100

Background:
CNC machine tools are most effective when multiple operations can be combined in a single setup. This is a simple matter when tool lengths are listed in the controller's tool table and referenced in the G & M code file.

The machine is referenced to the fixture only once, in this case the fixture is a machine vise. The machine does not need to be referenced when the tool is changed for the next operation, nor does it have to be referenced when the raw material is loaded for the next part. If the work offset is saved it can be called up at a later date. As long as the fixture is mounted at the exact same position on the machine and the machine has completed a homing cycle, the same work offset and tool table can be used.

Fixtures & Tooling:
In this application note we use 3 tools to manufacture a relatively simple part. This demonstrates a typical machine operation and shows good efficiency with a manual tool change. Run time of the part is about 12 minutes. The operation uses 3 tools and the PCNC 1100 requires about 25 seconds for a manual tool change. If the machine had an automatic tool changer with a 3 second change, the part run time would have been about 10.9 minutes (10% savings).

Read more:
http://www.tormach.com/MfgDatabase/20108%20multiple%20tools.pdf

Keywords:
Tormach, CNC, 6061, aluminum, tool change, quick change, TTS, chamfer, rougher, cobalt, finish cut, rough cut,
radius, scallop, surface finish.

Tormach on the web @ http://www.tormach.com

Overview:
A 3/4" diameter end mill is used to radius the corners of a thick plate, then the same end mill is used on a finish cut, finishing the 2" edge in one pass.

Material: 6061 Aluminum
Cutter: 3/4" 4 flute end mill
Titanium Nitride (TiN)
Speed: 500 RPM
Feed: 4 IPM
Machine: Tormach PCNC 1100

Background:
It is hard to define the operating limits of milling machine. The performance envelope is never black and white and success in the gray area depends on understanding the demands of the task at hand. In this particular case the desire to leave a good finish on the 2" face required at least 3/4" diameter end mill. Any smaller and the tool flex would have been excessive. Edge milling and finishing operations on 2" 6061 billet is not something we would recommend as a primary role for a 1.5 HP spindle, but if the machine frame is rigid enough, the task is certainly possible.

Fixtures & Tooling:
The particular task at hand was to put a radius the corners of a 2" thick block, followed by a full depth finish cut. The PCNC 1100 mill has been designed with frame rigidity that exceeds the stresses introduced by the 1.5 HP spindle. As such, we expected the spindle horsepower to be the limiting factor, not the machine frame or axis motion power.

Read more:
http://www.tormach.com/MfgDatabase/20107_Milling_6061_Plate.pdf

Key words:
Tormach, CNC, 6061, aluminum, heavy cutting, billet, finish cut, edge milling, R8, rigidity, end mill, horsepower, HP.

Tormach on the web @ http://www.tormach.com

Overview:
A 3/4" steel plate is finished on both sides. One side is a surface cut, the second side has 0.2" removed using 1.5" diameter face mill with high positive angle inserts.

This video reviews a surfacing operation using a high performance insert face mill. The task involved both sides of an 8" circular plate, one side with a simple finish cut, the second side removing 0.200" at 0.050" per pass.

Material: 1018 Steel
Cutter: K-Tool Insert Face Mill
Model OC-1575
Inserts: OPEB 535XP GR-X40
Speed: 1500 RPM
Feed: 10 IPM
Machine: Tormach PCNC 1100

Background:
Modern inserts with a high positive angle of rake allow high rates of metal removal with minimum power. High positive angle reduces the cutting forces, thereby reducing tool flex, horsepower, and improving finish. Longer machine life, reduced vibration, and higher metal removal rates are among the benefits found with high positive cutters.

Read more:
http://www.tormach.com/MfgDatabase/20106_Surfacing%201018_Steel.pdf

Key words:
Tormach, CNC, 1018, steel, mild steel, face mill, insert, insert mill, high positive, rake angle, surface mill, stock removal, K-Tool, OCTA cutters.

Tormach on the web @ http://www.tormach.com

Overview:
A 3/4" steel plate is cut to size and finished with two different end mills in the process of making an 8" chuck adaptor plate.

This video reviews a standard milling operation on low carbon steel. The task involves creating an 8" diameter circular plate from an 8.5" x 8.5" x 0.750" square plate.

Material: 1018 Steel
Cutter: Cobalt HSS rougher
1/2" 4 flute end mill
1/4" HSS 2 flute
Speed: 700 -1200 RPM
Feed: 1-4 IPM
Machine: Tormach PCNC 1100

Background:
Mild steel was used to make chuck adaptor plates. The process involved 3 operations using 1/2" roughing end mill. These were 1) cutting the circular shape from a rectangle, 2) squaring off a chamfer left behind by a face mill, and 3) finishing the outer diameter. Finally, we switch to a 1/4" end mill and put a precision cut on the pilot. Climb milling was used throughout.

Read more:
http://www.tormach.com/MfgDatabase/20105_Milling%201018_Steel.pdf

Key words:
Tormach, CNC, 1018, steel, mild steel, cobalt, HSS, high speed steel, edge milling, finishing operations, rotary table, pilot, end mill, rougher

Tormach on the web @ http://www.tormach.com

Overview:
Boring, pocket circular interpolation, and spiral down interpolation are compared in this application video for accuracy and finish.

This video reviews various methods for creating holes larger than can be done with standard drilling cycles. Three cutting methods are compared for speed, finish, and accuracy.

Material: 6061 T6 Aluminum
Cutter: 0.5" HSS drill
0.5" HSS rougher
0.5" HSS 2 flute
Boring Head
Speed: 900 to 2000 RPM
Feed: 1 to 20 IPM
Machine: Tormach PCNC 1100

Background:
Very large boring machines can bore and ream very large holes. When facing the task of creating large holes with a smaller machine, a machinist is faced with selecting between several alternative methods. Circular interpolation is an easy task for any CNC machine, but the resulting accuracy is strongly affected by backlash of the ballscrews and the precision of control. A boring head is slower, but generally more accurate.

This application note reviews the creation of 18 holes, each 1.27" in diameter. The holes are finished using three different techniques with the manufacturing results compared.

Read more:
http://www.tormach.com/MfgDatabase/20104_holes_6061.pdf

Key words:
6061, aluminum, boring, circular interpolation, bore gage

Tormach on the web @ http://www.tormach.com

Overview:
The surface finish and other aspects are reviewed in this video using a variety of feeds, speeds, and depth of cut while surfacing with a fly cutter using a C2 carbide tool.

Material: 6061 T6 Aluminum
Cutter: fly cutter, C2 carbide
2.1" and 3.7" diameter
Speed: 900 to 1200 RPM
Feed: 5 to 35 IPM
Coolant: None
Machine: Tormach PCNC 1100

Background:
A conventional fly cutter can be used for flattening a surface, rapid stock removal, or optimized for surface finish. The objective in mind will guide selection of feed, depth of cut, and cutter geometry.

Fixtures & Tooling:
The stock was held flat in a 5" machining vise.

Read More:
http://www.tormach.com/MfgDatabase/20103_surf_6061.pdf

Key words:
6061, aluminum, surfacing, fly cutter, roughness, finishing, surface

Tormach on the web @ http://www.tormach.com

Overview:
A 1" thick bar is cut in a single pass with a high speed steel rougher.

This video reviews deep slot cutting of 6061 aluminum bar using a PCNC 1100 CNC mill.

Material: 6061 T6 Aluminum
Cutter: 4 flute HHS rougher
0.5" diameter
Speed: 2500 RPM
Feed: 5 IPM
Coolant: Flood
Machine: Tormach PCNC 1100

Background:
The task at hand was cutting up 1" x 4" bar stock into smaller pieces in preparation for final machining. A bandsaw was not available, so the cutoffs were done on the mill.

Read More:
http://www.tormach.com/MfgDatabase/20102_Cutoff_6061.pdf

Key words:
6061, aluminum, HSS, high speed steel, end mill, rougher, cutoff, slot, slotting

Tormach on the web @ http://www.tormach.com

This video reviews FR4 with 1/8" carbide. Also known as G10, FR4 is a epoxy glass composite used in circuit boards.

This application video reviews edge cutting epoxy woven glass using a PCNC 1100 CNC mill. The application example involves cutting individual printed circuit boards (PCBs) out of a larger panel.

Material: 0.067" FR4
Cutter: 2 flute spiral carbide
0.125" diameter
Speed: 4500 RPM
Feed: 10 to 25 IPM
Coolant: None

Background -
Epoxy woven glass is a specific example of the general class of composites known as glass reinforced plastic (GRP). Similar composites using linen, cotton, or paper in a polyester or epoxy matrix are relatively easy to machine. Epoxy glass composites are more difficult to cut due to the abrasive nature of the glass fiber.

Printed circuit boards are commonly made using FR4 grade of epoxy glass composite. The multiple step process of manufacturing small circuit boards is made more economical by printing multiple circuit boards on larger panel and then cutting apart the smaller boards. FR4 and G10, a similar but flammable composite, are also used as structural materials. In thicker sections the materials are exceptionally strong and stable.

Read More:
http://www.tormach.com/MfgDatabase/20101_Cutting_%20FR4.pdf

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Grade G-10, FR4, Garolite, GRP, Glass Reinforced Plastic, epoxy woven glass, PCB, printed circuit board, edge milling, routing, tab routing, panelized PCB, palletized PCB