Nomad with deep DOC, shallow WOC

[gmack (Gerald Mackelburg)]

@Moded1952

I have a feeling this might be a factor in my issues with cuts with high axial engagement but low radial engagement. e.g. I have a 6x15mm 3-flute finishing endmill with a manufacturer recommendation of 12mm axial, 0.1mm radial at 10kRPM and 450-500mm/min. When I try that on the Nomad, despite seeming well within specifications (HSMAdvisor says this cut is 0.006Nm of torque and 0.006kW of power), it makes a ton of noise and appears to deflect from the wall. This can be seen visually, as if you let the endmill “rest” in a spot with the spindle running, it’ll cut itself a little “dent” in the stock.

I adjusted the endmill rake angles in Milling Analysis 0.9.1 to get it to match your HSMAdvisor results as shown here:

That would be really nice if that small chip thickness was achievable (it’s 1/6 what @Julien, @Vince.Fab, and others would likely use).

You might want to try reducing the axial DOC to smooth out the cutting forces as shown here:

Using Audacity, as shown below with you video, might also be helpful in analyzing forces and chatter.

I don’t know German, but isn’t nass (water spray) kuhlung (cooling) recommended for that endmill?

OOPs I forgot to mention that less cutter stick-out from the spindle’s connection to the gantry might help too (elevate workpiece too?)