Machining Cutters You May Have Never Seen - But Should Own

alright guys let's talk about some unique end mills and cutters that you probably don't have that you probably should have this is one of the ugliest things I think I've ever seen in my life but I tried one the other day and it got to tell you it was a win the other one that you've probably never seen or maybe you have is this guy right here this looks like something from a horror film this is called a carbide burr cutter and if you work with a lot of this material all you knife guys probably recognize this this is half-inch linen phenolic cutters like this are ideal for a material like this Lenard phenolic glass-filled phenolic epoxy based cloth laminates like this these can be brutal on conventional cutters like this and generate a tremendous amount of heat believe it or not I mean it looks like wood but there are there are countless layers of cloth here this is cloth this is le phenolic linen epoxy phenolic all of these layers of cloth are separated with a layer of epoxy resin and it put under tremendous pressure and squished down and there you have it this stuff is like glass as well so say it's glass hard but it's incredibly tough and it's not going to crack like like a harder solid material the laminate gives it an amazing strength and heat resistance but cutting it can be a challenge so this guy right here is the way to go if you're cutting g10 or le fine Alex this cutter will walk through it like you would not believe I have cut literally miles of material with this with this cutter this exact cutter and this thing is the sharpest the day I got it it's absolutely incredible a friend of mine recommended that a long time ago and I'm glad he did because it has saved my bacon if you guys out there your knife makers out there looking for this material and can't source it I have it here in this ya brown you want to call it I also have it in black usually half-inch so you need something give me a call now the benefit to this particular cutter this is a two flute right hand cut left-hand spiral and it does turn this way and you can see the spiral forces the cutting edge to come down from the top we're on a conventional cutter to flute here as it spins it lifts you can see it goes up now the benefit to using a cutter like this versus a cutter like this if you're cutting a thin material and it's doing that clapping sounds jumping around plastic thin aluminum whatever the cutter like this is going to want to lift it the cutter like this is gonna want to drive it down just like a karate jump okay this is gonna want to drive it down the other benefit is if you're cutting some softer materials that have a tendency to want to explode as the cutter is passing through it like would like a veneer plywood this is the baby to use now this is a two flute like I said and this guy here is a 1 flute now this looks like something that you ground on your first day of your apprenticeship and throughout the window so nobody would see it but somebody grabbed ahold of it and figured out what to do with it and there you go so this is a 2 flute right hand cut left-hand spiral single flute right hand cut the left hand spiral was exactly the same thing it comes down it shears down on the material and these are made for exceptionally high rpm several thousand rpms you drive these things suta material let's set up some veneer plywood run these conventional cutters through it see if it explodes the surface off of it then we're going to swap over to these guys and then we're going to put down a piece of thin material on top of that and compare the performance the chatter performance the lift performance with these different style cutters and then we're gonna put one of these in we're gonna cut some of this and we're gonna make a lot of dust I might even show you my homemade dust collector for my mill which I got at Home Depot works like a charm stick around in order to establish a baseline for the difference in the finish that you can achieve with these different cutters the first passing going to take is with a conventional 2 flute carbide high spiral and mill we're going to go a quarter inch deep this is a birch veneer plywood and with this type of cutter I can expect a lot of damage along the course of this country's 2,000 rpm - flute carbide right hand cut right hand spiral [Music] it is probably a good idea to vacuum this stuff away as opposed to blow it off well I'll take a second and do that okay now that is exactly what I had hoped this cutter would do to this material you can see that it has lifted and if you were doing something critical with this particular veneer you probably just stepped back from the Machine and gasps anyway let's put the reverse fluke cutter in there I'm going to go with the two flute reverse quarter cutter and we'll see exactly what that does right alongside this cut [Applause] okay for sake of illustration as it turns like I said on the bench you can see the cutting flute coming down from the top and there is a flute every 180 degrees so I expect almost no crown on this one this will also be a quarter of an inch deep 2,000 rpm check it out well when you turn it on its gonna look like it's spinning backwards so don't be deceived by that make sure you still continue to run the machine forward I know we vacuumed this off this is going to be beautiful some just hang in there all right well those results are undeniable - flute conventional - flute reverse helix and that is just absolutely spectacular there is no raise to edge on that whatsoever let's move over just a little bit more take the - flute replace it with a single flute try again and see if it makes any difference [Applause] okay this is a single flute once again cutting edges coming down from the top and I'm doing this demonstration on wood just to demonstrate the downforce of the cutting the ideal reason for this video is so that we can start cutting thin material and I can show you that these cutters are fantastic at keeping material on deck so it's not going to lift the chatter and jump around and bang like I found a lot of questions about that offline so I figured I would address it well let's see how this one performs compared to the other two just for yucks same thing two thousand rpm single flute two fifty deep [Applause] like nothing but without being right on top of that the difference is really hard to tell so let's put it on the bench magnify it take a look [Applause] okay I said the difference in the top birth the standard metal cutting bit just tore this stuff apart but the bits intended to do softer materials perform flawlessly the inside edge of the two flute here I can see that the channel is a little bit hairier you can see it right there it's undeniable the single flute is just beautiful top surface is fine I'm sure it wouldn't take a whole lot of effort to knock that back off of there if you went in there with some real fine Emery or took a second pass through it but I would say out of this particular footrace the single flute right hand cut left-hand spiral is your winner followed by the two flute right hand cut left hand and the quarter-inch conventional high spiral carbide just failed miserably didn't fail it cut it but it you know if you didn't want to crack your veneer and you just failed so there you go keep that in mind if you're cutting plastics I know this cuts really well with plastics if you don't want to spend time deep burning the plastic don't create the birth all right let's put a piece of le phenolic or excuse me let's put this back in the machine I'm gonna put a piece of eighth inch acrylic on this and I'm gonna come across the eighth inch acrylic and see if we can get it to jump around and try the exact same thing with these reverse flute cutters and see what it does as far as lifting and performance okay now the real reason for the reverse flute cutters although you saw how they perform in wood and I think that's helpful because every once in a while you're gonna do some wood in your shop this is a piece of 0.1 acrylic and you can see that it's not held down very strong now for all you guys that are going to say move the parallel closer to the edge or sandwich it between other material you're absolutely right but this is a worse case scenario demonstration and we're going to run this - flute this is the - flute hi spiral right hand cut right hand spiral carbide end mill we're going to run it across conventional and climb cut about say seventy foul into the park and we're gonna try to get this to jump around and chatter and I think it's going to be quite successful quite fast so let's get this thing to bounce around to establish a baseline on poor performance and we'll move over to the other cutters okay I know this piece is going to scream up a storm so I'm going to voiceover this is seventy thousand it's into the part 1.75 millimeters 2,000 rpm conventional pass watch the material jump around as the cutter gets into it you can see the trailing edge of the material is starting to vibrate and it's pretty clear by the waste material sitting on the part that we're cutting that this is jumping around it's pretty obvious when you're standing there jumping around to it it makes quite a bit of noise if this was a very delicate feature it would probably break off for safety I'm going to turn the cutter off while I inspect the edge the face could be a better finish if the parallel were moved closer to the edge and that jumping around was eliminated not a whole lot of chipping top and bottom but that's going to be driven by the material let's move in another 1.75 millimeters and do a climb cut and see if it makes any difference I did observe chipping on the bottom of the part this time and watch the end of the piece as the cutter gets close you can see that it is starting to jump around almost double the thickness of the material there was a lot of movement there the finish did start to deteriorate as it got towards the end because of the lifting with the upper edge not too bad bottom edge did demonstrate some chipping right baseline establish this is the single fluke left-hand spiral right hand cut we're gonna go 75 into it like we did with the quarter-inch carbide we're gonna go with a conventional approach initially and let's see what we get I do expect this to push down and not make a whole lot of noise I'll be surprised if there's any lift or noise whatsoever let's give it a shot alright keep your eye on the very corner of the material and watch forth the bounce as the cutter makes contact the material stays quite flat there's minimal movement and if you keep your eye on the chips that are laying on the surface of the material you see that edge forward of the cutter it's jumping around a little bit but the stuff laying on the surface is staying quite still very pleased with that so that those demonstrate that there is considerable downforce and not a lifting and dropping rebound you [Applause] upper and lower edges of the material still look pretty good but I got to say that that noise had to be the loudest of the cuts so far no loading of the cutter - which is good let's go another 70,000 to the part and climb cut this now I've gone to voiceover on these particular cuts because this is screaming like you would not believe it is making a incredibly high shrill now you can still see that even in a climb cut there is not much movement and the chips laying on the surface are staying still which is good it does indicate a Down force on that plate it is not lifting it which is good I would think for a thinner wall or a web type design on a piece of plastic you could be assured that you're not going to crack it so watch for the very corner to lift those we're coming off and it stayed right where it belongs very nice I have to say without a hundred percent without a doubt the performance difference is minimal climb versus conventional the edge is still really nice feels a little bit more material returned to the surface I think you guys know that means it's just not a very smooth finish like you would hope to get on a finish pass [Applause] I was looking for a whole lot quieter guys looks like these cutters are more suited for the wood work than for the plastic not lifting work but they certainly are more beneficial at times let's put the double flute in there just for yucks see what it does okay quarter inch to flute right hand cut the left-hand spiral 72,000 rpm let's check it out keep an eye on the underside of the corner on the leading edge of this and you'll see as the cutter moves it to the material it flows the bottom corner off right there on the trailing edge you see there's a Halfmoon crescent shaped pulled out this is relatively loud I'm putting my finger there because it's making a lot of noise but it doesn't appear that anything's jumping around and their chips laying on the surface of the part would support that I am advancing this plastic out from underneath that parallel between these cutters so that the amount of flex potential remains the same [Applause] conventional approach still a little bit of noise let's go with the clime approach 70000 sit direction see if it shuts it up [Applause] the noise difference in the client cut to the conventional cut is about the same you can still see that the surface of the material has some movement but not too bad the finish that it's leaving behind is not spectacular then you can blame that on the rigidity when you have movement it translates to the surface finish and it's just not ideal and see the crack in the corner let's see if this takes it off because it does removed it quite nice I would still like to see a finer finish on that but the top and bottom surfaces are not tracked so it did work out well but the single flute in my opinion was the better of the surface finishes between the two cutters okay to better demonstrate the down spiral benefit we're going to have the two flute quarter inch first we're going to conventional up across the front trough down the center and we're going to climb across the back and you can expect three different bird patterns on this as this conventional cuts across the front it's going to lift a burr up and it's going to roll a burr out so this edge right here will have two burrs one the top and one on the side the trough down the center is going to have burrs on both sides of the upper edges and the climb cut across the back is going to have a burr on the top edge but the backside edge at the base of the cutter is going to be almost perfect because the rotation of the cutter is driving the material in as it's cutting as opposed to exploding it out and you can see production part I'd be pulling my hair out and writing some more code to deburr that in the machine because that's pretty ugly let's take a look at the burrs rise promised the frontside as a burger exploded off the bottom edge because it's rotating out and lifting up so you have two birds to deal with there you can see it and feel it trust me now looking at the back that one burr is driven into the part therefore it is sheared off and non-existent that's almost a razor-sharp edge right there it's absolutely ideal but there's nothing you can do about these top bars when you have a right-hand spiral right hand cut it is going to lift like that sharper the cutter the better when you're working with Delrin or any other plastic and I've always liked two flutes over four let's put one of them single lip cutters in here and see what happens and you can bet that the bottom is going to be absolutely atrocious but the top bird is going to be almost non-existent single oh okay this is the single flute reverse helix cutter we're going to do the same exact path conventional cut across the front a full-contact trough down the center and a climb across the back we're about 300 deep this is a 250 diameter projected you're not going to be able to measure with a micrometer but that's what they call it any unfavorable result that I could expect right now I would think that the cutter is probably going to pack up and explode going down the middle I'll be really shocked if it doesn't other positives should be an almost absentee burr across the top because of the down shear and the climb cut in the back should be almost perfect as opposed to these two this one will be I would say noburo long the top trough in the center but on the front you can still expect the burr to kick out because of the rotation let's see if I'm right all right this one's gonna want a closer look on the benches I think the advantage of the down cut is going to be clear and blatantly obvious you get a close-up on that let's go to the bench and take a look okay let's take a look at the quarter inch - flute first I would say it's a real nice finish on that we do have raised the edges as you can see the edge right there right there you can see it across the back as well so with this conventional spiral it is going to raise a burr the front also has some protrusion from the rotation the back does not the rotation did make a huge difference in the back finish is good but the burrs are going to cost you some time on the bench now I purposely made a thinner wall in the back on this one so I could tell which was the climate which was the conventional conventional cut looks really good across the top I think you can tell immediately that there are no no raised edges on the top of this part you'll see a nail test we are golden absolutely beautiful conventional cut appears to have given a better finish a little bit of noise at the bottom but that's a fairly substantial cut for how rigid that cutter is in the back we can blame a lot of this chatter on the wall thickness this was probably moving around quite a bit it is fairly flexible as I sit here there's no shelf burr pushed out the back and realistically nothing pushed out the front either so those reverse flute cutters worked very well this is another sample that I did with the two flute left-hand spiral and it tore it up pretty good in the front that's the conventional cut so it was digging in as it was coming around minimal burrs on the top minimal burrs on the front definitely not the surface finish on the side cutting performance the back I did two passes I did an initial 200 deep and then I went back and did a tenth out deep some of the noise from the original pass the first pass was showing through but it still has that burr on the bottom these cutters are not known to give decent surface finishes on deck but there is a cutter called a combination cutter that will give you better results if you want to look that one up I have no use for those but those are pretty interesting to give you a floor cut and a wall cut and a top surface down shear and it's an interest in cutter all right let's grab a piece of le phenolic show you what that burr cutter does it's pretty cool to have in your box they look all right let's take a look at the performance of the half inch burger cutter in the Le phenolic I'm going to run this at 2,000 rpm as well I'm going to cut this piece in half so this is a full bite cut and as you can see it really doesn't matter conventional or climb on a full depth through the center so let's see what happens [Applause] I will be running the shopvac for this so I'm going to cut the sound down on the video and this is actually pretty quiet I'll take one of these halves off and I'm going to show you what kind of surface finish to expect using this type of curve [Applause] let's get right down on it check it out man [Applause] the edge is absolutely beautiful there is zero burning on the inside of that that was not sped up that was real-time and this material can be quite tough on standard cutters but this little guy right here that thing is amazing let's pull one of these off put it on the bench and show the finish and I don't think you can complain at all about that finish that is absolutely beautiful there is a slight raised feeling on here I don't know if I can actually get that on a camera or not this is not glass smooth like you would expect with a nice - flute or for flute carbide when I do these pieces and I do a lot of these guys when I do these I will run the perimeter with that cutter and then I will finish it up with a - flute carbide and it gives a glass smooth finish on the edge this little mark right here is when I stopped momentarily to check the camera frame so there is a substantial load on it but that cutter walked through this material like it wasn't even there I couldn't even told you when the cutter was making contact if it wasn't for the sound absolutely flawless and no heat not burned at all just beautiful you don't have one of those cutters get one you're going to be happy if you ever have to cut a phenolic or a limit Landon linen glass epoxy base laminate like this you're gonna be glad it's in the box thanks for watching you

Channel: Joe Pieczynski

Views: 64,240

Rating: 4.942029 out of 5

Keywords: Joe Pie, JoePieczynski, Advanced Innovations, advanced innovations llc, how to, machine shop, shop tricks, shop hacks, shop techniques, shop tutorials, end mills, le phenolics, micarta, burr end mills, router bits, wood working, reverse spiral cutters, laminates, G 10, knife makers, cnc routers, cutting composits, down spiral bits, diresta, ave, avee, furze, savage, abom

Id: -u-R3xd6KB0

Length: 30min 5sec (1805 seconds)

Published: Tue Apr 28 2020