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Toolman

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This is 1040 high carbon wear plate. They are guide rails for a steel rolling mill.



First I square up the hardened flame cut sides as far down as I can go without hitting vise jaws.

Then fly cut top surface with 4" face mill which did not work so well. Started picking up a chatter and had to slow down speeds and feeds too much. Decided to go with a 2" face mill that worked bitchen'. Got a real good chip and a great finish. The plate was too hard for a big cutter. Too much contact area.

Plates had a big 45 deg chamfer along the long sides which I kellered with the tool is used in the first op then matched the ends to the first op cut.

Palletized and DONE!!!

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wsuwrhr

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Coolant with inserted carbide tools on steel?
 

wsuwrhr

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Coolant on or off on steels depends on surface footage. Generally above 400 sfm coolant off!
Hmm. I've never used a wet insert for steel due to thermal shock.

Brian
 

billy610

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Hmm. I've never used a wet insert for steel due to thermal shock.

Brian
Inserts won't get thermal shocked if your not running fast...we generally use between 400-500sfm as the point where coolant gets turned off on steels.
 

wsuwrhr

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I guess I don't know slow in machining. :)
 

billy610

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I guess I don't know slow in machining. :)
That's a good thing!!! haha

Now if you want to see fast on tough material, check out turning Inco 718 with ceramic. I have a customer running about 1300 sfm on 718!!! It's awesome. I was at a Sandvik seminar recently and they have run ceramic up to 3000 sfm on 718!
 

wsuwrhr

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That's a good thing!!! haha

Now if you want to see fast on tough material, check out turning Inco 718 with ceramic. I have a customer running about 1300 sfm on 718!!! It's awesome. I was at a Sandvik seminar recently and they have run ceramic up to 3000 sfm on 718!
When you are doing it right, the heat goes with the chip.
 

billy610

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Exactly...but when using ceramic on inco at over 1k sfm EVERYTHING is glowing bright orange!
 

wsuwrhr

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Exactly...but when using ceramic on inco at over 1k sfm EVERYTHING is glowing bright orange!
Ceramics don't survive interrupted cuts so they are only plausable in a lathe, so it don't apply here in this thread. :)
 

billy610

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Ceramics don't survive interrupted cuts so they are only plausable in a lathe, so it don't apply here in this thread. :)
We just milled with ceramic button inserts at the Sandvik seminar and they do survive. Ceramics are progressing, but admittedly there application window is very small.

I could go on all day about this stuff, it's fun.

Time to stop the thread hijacking.
 
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