Denford Software & Machines

Here is a useful guide to what spindle (RPM) and feed (mm/min) rates to use on the most popular materials.
It includes both Denford milling machines and routers as well as tips on what to do if you have problems.

NB It is intended as a guide only, you will have to make adjustments for your own particular setup - we will not accept responsibilty for any damage which may occur as a result of using this guide !


http://www.denfordata.com/pdfs/SpindleS ... Insert.pdf (700Kb)

Router 2600 PRO - We have experimented with various endmills for cutting aluminum for making gearbox components, parts and mounting brackets for use in robotic competition. Mounting a piece of MDF to the machine table to act as a sacrifice/fixture, the aluminum sheet was screwed down with wood screws. After cutting shapes, lines, and milling pockets with different endmills, the Niagra Cutter # 85351 gave the best cut and finish with a FEEDRATE of 8 IPM (inches per minute) and a 15 step down at 18,000 RPM. The Niagra cutter was 1/4" x 3/4" flute, 1/4" shank, 2 1/2 OAL / 2 Flute - SE - center cut - 30 degree helix / solide carbide - TiALN coated.

Only cut aluminium on the 2600Pro and Compact 1000Pro

Damage will occur if you do this with the Porter cable motor as chips can get into the motor!!!

There are several articles on our technical forum that relate to this. See viewtopic.php?t=787&highlight=feeds

Aluminium is always difficult to cut as it is soft and tends to clog the tool. You are better to use a larger diameter cutter with a spiral flute. 6mm would be ideal. Solid carbide is better than HSS as it will last longer.

The material must be clamped down very securely to ensure there is no vibration.



I would try about 12000 RPM and look at 600 to 800mm/ min.

Take the depth of cut to about 1 or 2 mm.

Depending what you are trying to do the problem can be caused by the chips being trapped and rubbed against the side of the tool causing friction.

You can experiment cutting manually by starting the spindle at top speed then turn it down with the speed override knob and then setting the jog feed at say 2000 and turn the feed override knob down so it is going to cut at 600mm/ min

Manually take a cut about 1mm deep and turn the feed up slowly with the feed override knob to find the best result for the material.

You can experiment with higher speeds until you find what works best.

Every material is different and there is not a set feed and speed we can recommend that works every time.

Sheet material tends to be a lower grade and will not be free cutting.

Buying the correct material may be more expensive but will save you money on cutters in the long run.

Best Regards,

Steve Oddy

I would add it is always a good idea to blow the chips away so the cutter doesn't have to cut them again, also a lubricant will help as it prevents build up on the cutter flute/s which if that happens it will leave a very poor finish. Flood coolant does both jobs but is not possible on all machines.

Triac

Steve wrote: ↑

Mon 11 Feb , 2008 13:35 pm

Only cut aluminium on the 2600Pro and Compact 1000Pro

Damage will occur if you do this with the Porter cable motor as chips can get into the motor!!!

Will this happen on the Denford 2600 ATC? Should aluminum be milled in this machine or not?

This had me wondering as I have the Mircrorouter Pro with a PC motor, I thought the Pro version was OK for alu but not steel. I would have thought putting filter cloth over the vents would have been OK. I use off cuts from the cooker hood filters in the kitchen for the fan filter, sticking them on the vents would stop swarf getting in.

Pete