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I finally stopped scrapping aluminum parts by changing one thing in my G-code
I was running a batch of 200 aluminum brackets on my Haas TM-1 and kept getting chatter on the finish pass, scrapping about 15 parts a day. I tried slowing the feed, swapping inserts, even re-leveled the whole machine twice. Then a guy I know from the local machinist meetup in Springfield told me to try ramping into the cut instead of plunging straight down. Changed one line in Fusion, added a 2 degree ramp, and ran 50 parts with zero chatter and a finish that looks like glass. Has anyone else had luck with ramp entry on aluminum, or do you use a different trick for chatter?
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angelar5727d ago
Read a thread on Practical Machinist about this last year and the old timers were saying the same thing. Plunging straight down hammers the cutter and the part, especially in aluminum where the flutes load up and start singing. Ramping spreads that load out so the cutter eases in instead of slamming. I run a 2 to 3 degree ramp on just about everything now and my insert life went way up too. One thing to watch is your ramp length, if you go too shallow the tool rubs and you get worse chatter than before. Sounds like you found the sweet spot on that TM-1.
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