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Routing Brass Plate10/16
I have a small job were I have to rout a number of letters out of 0.05" thick brass plate. The letters are very small (Approx 5/8" sq.) and I have to use a 1/16" diameter tool. The plate is glued down to a piece of solid wood to prevent the parts moving.
Any ideas on feeds & speeds? Also do I need to use coolant? etc. etc..
Buy more than 1 bit.
Use an O flute.
Machine with the back of the letter up and go into the wood block 0.040 or so.
I would not go over 12,000 rpm and 0.002 to 0.003 chip load (24 to 36 ipm). I found that using that same chip load in aluminum works fine to 12K but won't work at higher speeds.
That's where I'd start and recalculate any or all the above after it messes up. Except for the buy more than 1 bit part.
OK. Definitely with you on the extra tools! I started this project with an O flute that my customer supplied and followed the speeds my regular tooling supplier suggested (18000 RPM, 25IPM). Cut was good but the bit snapped very quickly.
Then I used another tool from the customer while I waited for my supplier to deliver more. This was a straight 2 flute bit. I ran at the same speeds and the cut was horrible, lots of burring and again it snapped.
Now I have purchased 5 more tools from a different supplier, these are stub tools to limit vibration and are 2 up spiral flutes. I have been advised to run them at 24000 RPM and 30-38 IPM.
So now with your speeds Dropout I am thoroughly confused! I will start of with what the tooling guy has suggested and see how it goes! I will be cutting tomorrow so I will let you know.
Don't forget that we're cutting metal dry.
Try the lower rpm and see what happens. You might be surprised.
OK. Seem to be having some success.
Just to help the next guy I used 15,000 RPM with a ramp in at 2 IPM & cutting feed of 6 IPM. I also blew compressed air into the cut.
I will post pictures of the parts & the tool.
As promised here are the pictures of the parts and tool.
So the tool is a 1/16" diameter and the parts are approx. 5/8"x5/8"
Hope this can save someone else some headaches!