Spent the afternoon browsing various threads and videos trying to home in on settings to work with and would like some advice perhaps. I wasn't able to get much solid information on the ER11 as most seems to be for the Dewalt or other machines completely. I'm cutting aluminum, 6061 mainly and what I've gathered from one of the videos recommended in another thread (after cutter choice, 1/4" shank, 2 flute carbide upcut) is: Feed Rate: 96-100 IPM Depth of Cut: 0.075 (1.9mm) Spindle Speed: 16000rpm (Dewalt) (ER at 18000?) Ok, thats fine I think? (correct or advise if needed, too slow, too fast, etc) but, the ER11 has a better range and want to use the possible features to the fullest but also figure ramping up for too much speed might affect the lifespan of the brushes and degrade quality? I'm perfectly fine with those settings if they are good, but if Im leaving something out I should be considering... I guess what I'm fishing for is things to consider for things to try if I wanted to increase efficiency or speed without beating the hardware up. I also have 1/8 shank mills handy but would like to know if thats a suggestion, why. Thanks for chiming in ahead of time-
Don't know if this will help - cutting 6082 (similar properties to 6061) I use a straight, 2 flute 6 mm or single flute spiral upcut 3 mm carbide bits at 12500 rpm, 0.2~0.5 mm doc, 500~1000 mm/min (20~40 ipm). I'm sure I could up that feedrate. The most important factor I find is using coolant - isopropyl alcohol or meths - I tried WD40, but found it made the chips sticky and difficult to clear. A lot depends on the rigidity of your machine - if you have a large machine work in one corner if you can where there will be less flex in the framework. Alex.
Your cutting parameters also depend on what cutting strategy you are using, contour, pocket adaptive etc. The ER11 should preform a lot like the dewalt or makita. The parameters you list above don't sound bad to me for adaptive cutting when used with a optimal load of around .025, however they sound to deep for pocketing or contour cuts. Here are a few videos that have helped me out, the guy is using a different brand of machine but it similar enough that his recipes should work on your machine. I really like using coated endmills like the one openbuilds sells for cut aluminum. AND... I find that the single flute is way more forgiving, just sure make that your recipe allows for the correct chip load for a single flute. edit to add links to the endmills I really like; Upcut Single Flute Solid Carbide End Mill 1/8" Diamond Carbon https://openbuildspartstore.com/upcut-single-flute-solid-carbide-end-mill-1-4-diamond-carbon/
Thanks guys- primarily I'm just cutting plates in thin stuff ( 5mm to 8mm) and a few holes (brackets, etc) so nothing needing pockets or contours. I did grab some 0 flute upcuts (1/4" shank) so intended on working with those.
