End mills for alluminium

[Bill PudneyParticipant @billpudney37759]

Just before I retired, it was suggested that we investigate the use of air blast instead of liquid coolant. The advantages seemed to be many, but principally it revolved around the mess that liquid coolant made, and the cost of cleaning up afterwards.

Sadly I left before anything happened, I wonder if anything did happen?

Merry Christmas

cheers

Bill

[Anonymous]

Posted by Neil Wyatt on 22/12/2017 22:06:42:

Is there any reason why we don't use air blast in our wokshops other than conservatism?

I can think of several:

I suspect a significant number of MEs don't use flood coolant of any sort anyway

Directed in the wrong place air blast will drive swarf where it isn't wanted; on the machine is one thing, in the face is another. How many people here use eye protection when milling?

It would be a pain to have to fire up the compressor, with associated noise, when you only want to use the mill for a one off job

Some people may not have a compressor

Many workshops seem to be so pristine I wonder whether they ever get used, let alone have coolant or air blast running

Andrew

Edited By Andrew Johnston on 23/12/2017 10:54:23

[Involute CurveParticipant @involutecurve]

On my Hurco at home I pretty much run flood all the time with ali, unless I'm finishing a surface and want a mirror finish for this I use WD40 which I buy by the gallon, at max the flood rate is 4 lpm, I can run at this rate continuously without fear of running dry or overflowing the bed, my sump holds about 16 litres, the paper roll filter system I fitted a while ago (on this forum somewhere) made no difference to the flow rate but my coolant now remains very clean and tramp oil free.

I have a mister at home but don't like using it as it makes me cough after use!!

For Ali I always use un coated HSS cutters.

To avoid larger pieces of scrap that break off getting pulled in mainly as the job separates from the parent material I use conventional cutting with 0.3mm oversize left on the part, that way the scrap is pushed away from the job and doesn't get pulled into the flutes, I then finish to size climb milling, often but not always with a larger depth of cut, depending of course on the particulars of the job.

In my former life we used both air blast and flood depending on the job, the advantage with machining centres is the enclosed environment allowing much much greater flow, effectively blasting the chips away, also with through coolant, pressure can force the chips up the flutes allowing much greater feed rates especially when deep drilling.

Shaun

[JonParticipant @jon]

Totally agree Andrew.

Shaun my lathes ok but cheapy busted up mill i have to leave close on 0.1mm then send cutter down climb milling with bed locks nipped up.

Thru coolant on cutters is a revelation most wouldnt comprehend the difference it makes.

Misters after trying some years back are a waste of time on lathe work but if just turning o/d, cleaning up and finishing they may be ok for some. If putting more than a cleanup cut on, its generating heat no mister will keep restrained therefore defeating the object. Production environments use massive systems in comparison and as many as 4 nozzles, tells you something and not used for boring!

If your coughing after use check the misters not going airborne, can be highly dangerous. Might get some usable flow then, as said dangerous to breathe in check it out.

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