There is so much that can be said about every aspect of this setup in order for this to work. The machine capabilites, the workholding, the tool holder, the grade of carbide of the tool. All of it had to come together to make this happen. Incredible.
@ajwilson605 air blast is coolant. Many coatings used nowadays needs a little bit of heat to work properly and prevent built up edge. Liquid coolant on this process would destroy the cutting edges in minutes due to thermal shock.
Mine can't either but they begin spindle stalling at anything over 3000 mm/min in anything harder than plastics and with any meaningful tool engagement. You need powerful servos but you also need an insanely powerful spindle with high torque for shenanigans like this
i still remember the first ever 200 IPM in Haas machine on aluminium 😎... now it's 10X on steel 😱 this is what Titan always says raise to greatness.. machine greatness... see the smile on his face 🙂🙂 like never before.. good work barry.. hats off 🤙🏼powerful Peoples make places powerful 👍🏼
Everytime I start getting discouraged about going into the CNC trade(still an apprentice) I just pop up titans of cnc and watch the awesome stuff you all are doing and it gets me right back into it! Keep up the great videos!
You're pretty much set for a career, most of the engineering automation has already happened, the next revolution that will pull millions out of work is in the soft fields like journalism, banking, graphic design et cetera etc
I can't believe that that tool is doing that kind of machining. The accuracy of this machine tool has to be very good to do this kind of dry metal machining.
Great content! Thanks for showing the world what’s possible, too many shops have guys running tools at lethargic MRR because they haven’t began to understand the full potential of the machine, work holding and tooling solutions.
This is really insane, but in my opinion the 1000IPM on the 3/8 Cutter was way more insane it had nearly the same MRR with 40 compared to this (48) but at HALF the diameter so way more fragile tool. But still a great video love those limit checks
This reminds me of the 4 minute mile record that literally took forever to break which was in 1954. Athletes be like 4 min mile? pffft that is impossible which is why the record stood for so long. But since that day in 1954 1,755 athletes have broken it. Surely with the advancements of technology in the machines and tooling this is a really great example of pulling a Morpheus from the Matrix "I'm just trying to free your mind" approach. Granted I don't have a spare Heller sitting around my garage to attempt this nor would I consider it looking at the expense of a tech coming out to repair my machine afterwards but I like the point you guys make. It's ok to push things harder and faster. As always much love and gratitude. 💥💪
Barry! I'm so amazed of how much thought is behind it. Firstly You picked a steel grade with around 0,75% carbon and high manganese content for its low ductility to provide good chip breaking and to avoid tool pullout. Secondly You used a finishing tool for it's small edge radius to minimalize cutting forces. Am i right that You picked the axial and radial DOC to have some spare torque just in case? Those are just my first thoughts but i bet there was a lot more behind it. BTW in those vices the workpiece was never going anywhere. Greets as allways, You Guys rule!
More smaller flutes also means the core of the tool is larger and more solid. But you have to take a hell of a lot into consideration before hitting the yeet button on a cycle like this. OMG scary.
It says in the video 1080, but in the description it says "This 15 flute end mill from Kennametal takes on 1018 steel attempting to reach 2000 IPM in our Heller HF 5500 beast mill." @@Jatsekusama
Titan, Barry.....awesome, doing crazy and showing crazy is what i think it takes to break the current mold and bring manufacturing back to north america. ❤
If it was slotting , I had a feeling it would break immediately but since it’s doing the periphery, I had a feeling it was gonna last doing that. I never knew they made a 15 flute endmill
What's the material removal rate vs a conventional feed? I feel like you could remove the exact same material per minute with a conventional tool path.
That's what I was thinking as well. Those are needles coming off that thing so it isnt much of a cut. You could take a bigger cut with a slower feed rate. My question would be which is wearing the cutter out quicker? Titan doesnt have to pay for cutters as they are given to him from the manufacturer to demo. So that cutter (if its a 3/4") costs 330 bucks on MSC and a shop that has to pay for that thing has to consider that. Also machine wear. 2000 IPM puts a lot more wear on everything than 500ipm and so on. I think most shops would opt for a insert type cutter in this situation. Inserts are cheaper to change and usually have at least 4 sides as well. Once that thing is dull it has to be resharpened and that costs even more. I have to pay for my cutters. Just my .02
Woow...!! You are crazy guys, but really, you inspire me and my guys to go beyond. We never know so far we can go until we try it. Thanks guys for this inspirational video..!!
Great job guys.... Boom! Bang! Funny how things go. I can remember the history of tools and machines. Cnc machines could do more then the available tools 30 years ago. Then the carbide grades getting better and the machines were to slow in speed and processor capacity, a corner was some strange form but nut 90°. Now the machines getting quicker and quicker with the "thinking capacity", better processors, rigid frames and stronger motors...... I see it as an constant battle between machine builders and tool manufacturers 😅 Let's see what in the coming years happens, I think very interesting stuff 😊
That was probably the smoothest sounding run in steel I have ever heard. Absolutely no bogging down on the spindle or the axis servos. A shot of the load meters would have been insightful.
Nobody done it before, since the CEO never let anyone, try, without forking the money out of their pocket for when it fails. That's why the Titans are up there, since HR people that got their degrees in "emotional damage" and "buhuhus look at me, I am sad", are not involved in the production and management of the people and the product. To be in the top, is once again proven by Titan, by pushing boundaries and sharing their success with the clients and employee's. That's a tribe that I would be proud to be part of. Keep on going, may fairness always be part of your core creed.
That's nuts crazy quick all good sounding cuts no squawking an the tool look just as good as new. what did the MRR end being? our machines haven't even got rapids that move that fast.
Makes me proud to see that German quality still exists. Heller makes crazy machines and just around the corner from me aswell. Southern germany still rocks when it comes to high tech machining in metal, software and engineering.
Try putting it in an ER-collet 😂 I think the rigidity of the tool-holder and the part itself helped a lot there. The tools can often take a hell of a beating if you do it right. Some times I just go for the sound and load, then see how the tool looks after 😂
The first time I was drilling with a carbide coolant thru drill the math worked out to 30 ipm feed into a part.... the most nerve wracking thing I have ever done because there wasnt the ability to fix this part. Now that fast is common
WOW - The material removal Rate - BOOM Spindle bearings also be like BOOM ha ha. Great job. Def worth a test to see whats possible !! It looks like 2200 is possible
If you've got the RPM, the torque, the table drive speed, and the rigidity, you can hit your chip load target and the limit becomes heat management at the cutter edge and ultimately the dynamic pressure on the cutting edge. Cut faster, it has to increase.
never would call myself a cnc operator but i did .100 deep 4 inch dia at maybe 1,100 rpm at 20 ipm with a custom index cutter that I made on a prototrak bridgeport. I know very well thats nothing but i used kennametal inserts which are the bomb imo.
So you’re little spec page says “1080 steel” although Barry said @5:10 that it’s 1018… they’re not much different but I can’t help but notice. (In this trade you have to be real particular as y’all know)
5:16 Got ‘em, but they do look worn AF. Can’t really expect better out of a finishing mill doing all of it’s own roughing completely dry though. You guys violated that tool. 😅
The part and the tool are the star but look at the faces of the boys in the background..they see pushing the limit most days….. but this one had a few jaws dropping and then stare of unbelievable amazement. If this team is going wow then then rest need to tug the forelock in respect.
I would like to see a video on how you come up with your parameters for your tools. I know Kennametal has the Novo but I haven’t used it much to know how to really get the results I’m looking for. Like for your high efficiency tool paths, or if you want to do a helical plunge and so on.
They were saying how the machine is scary fast. At my last job I worked on a Makino and it had a 4,000 ipm rapid. It was hard to get used to flipping the parts on the other side because the whole machine would be rattling and shaking around me
The dude's voice sound just like just like one of my besties and it is tripping me all the way out I would probably almost not even know which one was which I would for sure definitely no but I just I can't get over it that's the second time this week that still happened maybe I should give him a call❤
it's a reasonable 0.103 ipt the radial engagement is very low at 0.020 but the sfm is prety high at 2552 the big diameter will help with chip tinning add the high flute count and you'll get to 2000 ipm as I said the feed per tooth is reasonable it's the sfm that will wear out the tool quicker than it should and that's why the titanium coating is key for the success of this cut hence the high sfm, I'm just saying that this is not sorcery it's just engineering, the engineering of this cut is amazing trying to make something do crazy things it wasn't made to do like this tool that is made to finish titanium is being used as a steel rougher.
You make it like 1018 is tough, only because you compare it to leaded (you coud perhaps go even faster) or Chinesium which might seem easy at first until an inconsistency eats your tool.
That was fun, but the finish looked a little rough. Not sure if that is how its supposed to look but it would interesting to see at what rate of feed the finish smooths out.
2000/13,000 = .1538=IPR /15 = .0102 chip load. Definitely doable. With the step over we should be able to calculate tq and hp required. sounds butter. Is that HSK A63 tool holder?😅
