0.500 1018 cold rolled plates VS stubborn dude with too much time on his hands.
These parts were designed as weld on steel chassis mounts for a lightweight tubular engine crossmember. Customer knows what he wants and price isn’t an issue to an extent. Why not spend like 40 hours on tiny parts…why not
First I designed them in carbide quickly, tested, then designed in Fusion. Cut from aluminum to fit chromoly tubes and help envision workholding plus figure out CAM. Now I’ve cut a low profile vise to hold the steel for the first op and am designing a threaded 3d contoured plate to bolt the parts down for second op.
Decided to do a bolt down fixture plate setup because honestly I didn’t want to slot a 2d contour pass with tabs due to the plunging. Also practice with odd setups is helpful for learning.
We already have pre orders for four of these completed crossmembers with the first customer paying for material and consumables (endmills, metal). I bought two 1/4 Fireplugs and a 4 flute steel ball endmill from Lakeshore Carbide. The fireplugs have awesome reviews and I want to be very nice to them, predrill holes.
So…good motivation to get this S3 to cut steel.
Setting up cam in Fusion right now and 0.001 tho per tooth is 15000rpm @ 60ipm. I think I’ll set up the adaptive around 0.010 opt load and 0.020 doc to start. Going to try a few different types of coolant to see what works.
All milling will be done with the HDZ so I’ll get to see how ridgid it really is.