Sample Dashboards |
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Here are some Dashboards grouped in pairs (one in three's) that you can open on one screen and show the differences. The main takeaway should be not which is the better tool or machine, but rather that you cannot predict what combination is better or best without a tap-test.
There are 7 total sample Dashboards, 4 in a Haas VF3SS and 3 in an Okuma M560V. The endmill stickouts were the same in the Haas and the Okuma. The toolholders were the same 1.75" projection, however the Okuma was BIGPlus dual contact and the Haas had a standard gap. We recommend that you open the dashboards on your screen at the same time in separate browser windows as shown in the video below. Here are the demonstrations you can perform.
There are 7 total sample Dashboards, 4 in a Haas VF3SS and 3 in an Okuma M560V. The endmill stickouts were the same in the Haas and the Okuma. The toolholders were the same 1.75" projection, however the Okuma was BIGPlus dual contact and the Haas had a standard gap. We recommend that you open the dashboards on your screen at the same time in separate browser windows as shown in the video below. Here are the demonstrations you can perform.
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Identical 1/2" 3 flute stub length endmills in N1. Set to full 0.625" depth of cut and a full slot. The Haas is stable at 10,500 RPM while the Okuma can run stable at 8000 RPM. 39.53 vs. 30.12 cubes. The lower cost machine and toolholder performs better in this instance.
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Identical 1/2" 5 flute stub length endmill in P1. Set to full 0.625" depth of cut and 20% radial. The Haas is stable at 9550 RPM while the Okuma can run stable at full speed 15,000 RPM. 11.98 vs. 18.82 cubes.
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Identical 1/2" 5 flute long endmills in P1. Set to full 1.25" depth of cut and 10% radial. The Haas will be stable around 9200 RPM. The Okuma despite having dual contact (BIGPlus) will not be stable at full depth. It must be lowered to 0.300" to be stable. 11.5 vs. 3.2 cubes. Trochoidal milling in the Okuma would not work with this combination.
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Here are three Dashboards in the same Haas model with the same toolholder and the same 1/2" 3 flute endmill design, but in three lengths. Set all three to the same 0.500" axial depth of cut and 40% radial. The short endmill can cut stable at 11,990 RPM, the medium only 5700 RPM and the long only 420 RPM. The MRR ranges from 0.51 to 6.87 to 14.44 cubes.
Note that endmill manufacturers do not change their recommendations based on the tool length, but maybe they should.
Note that endmill manufacturers do not change their recommendations based on the tool length, but maybe they should.
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Here are two Dashboards for the same 5/8" 4 Flute Carbide Endmill in the same Toolholder, both in a Haas VF2-SS. One is set for N1 (aluminum ) workpiece material and the other for P1 (steel). Set both to 0.625" axial depth of cut and 0.125" (20%) radial width of cut and note the differences in stable speeds. Now lower the axial depth on the P1 Dashboards and notice how it reveals the same stable pocket at about 7700 RPM as the N1. This flexibility and frequency of the tool does not change, but the amplitude of the deflection does based on the material.
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Presentations
Here are two Powerpoint presentations for your use. The chatter presentation has video demonstrations of tap-testing and the impacts from chatter. The contactless tap-testing presentation demonstrates the protocol to address COVID-19 concerns about access to shop floors.
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