Use of the Fly Cutter on the Milling Machine

you so as most of you know I've been hard at work on this latest project tutorial series the carriage stop now that's out of the way I'm going to get back to a little bit to the instructional videos like I started out with and the project tutorials are good in that they show how to apply a lot of these machining operations that you learn to the in a real-world situation but it's good to have a little bit of the theory behind it before you start as well so that's that's what the instructional videos are for so I'm going to get back today I'm going to get back I'm going to do it do it in an instructional video on how to use the flight cutter it's pretty basic but I have a lot of requests for it so I'm going to get around probably get finally getting around to doing a video on both grinding a tool and actually using the flight cutter on the milling machine so that's what we're going to be doing today but before we get to that I'd like to take care of a little business number one my youtube channel just blew through 10,000 subscribers so I'd like to thank you guys for that all the participation as well you guys ask a lot of questions you keep me busy I try to answer as many as those of those questions as I can and hopefully I stay on top of them hopefully I answer as many as I can anyway and help you out so that's great when I started out and I never thought I'd see the day when would get this big but it has and it's pretty exciting I'm having a blast so we'll plan on keep punk I'll keep pumping them out as long as you guys keep watching it I was at another another order of businesses video or so back I was using this kala block and a lot of the viewers noticed that I was using a pair of pliers to tighten up the nut on it because I didn't have a spanner wrench to fit so there were a few complaints and harassment cebause it but one of the viewers stepped up by the name of Dale and made me a wrench for it ok I got it in the mail the other day apparently had some of these wrenches forged the blanks forged up and so we finished one up for me put pin in it it works great so now I have spanner wrench to use on my collet block thanks Dale so let's get started on this fly cover video so this is just a basic fly cutter there are many different styles this is pretty common just you know uses if this one uses a 5/16 tool bit and it just melts in a slot three set screws to hold it in place and flight cutter is real handy they they do a nice job on large pieces of work for like facing off the top surface of a part and they're pretty handy I mean if you had to buy an end mill this size it would cost you a fortune but the flight cutter all you need is a lathe to a bit and you can do some machine some pretty large parts economically so I think what I'm going to do is will run over the grinder and I'll I'll grind this tool bit um I did put a reference sheet on the web website you know if you've seen it or not but gives all the various angles clearance angles and feature angles of the the tool bit for a fly cutter so we'll use this to to grind it to a bit I got lazy when I put this together and I just used an existing right hand tool bit well that's actually backwards I mean with if you put a right hand tool bit and the flight cutter you have to spin it counterclockwise instead of clockwise the cutter doesn't care it'll work either way but if you want to spin it clockwise then just grind the tool bit opposite you know opposite hand maybe I get have some time I'll switch the thing around but you know it's no big deal it'll work either way cutter doesn't care which way it's spinning so let's go over the grinder and grind up this tool bit okay so as I said before this is pretty much the same as a turning tool the difference is there's no side there's no side cutting edge angle it's just straight along the side so let's grind this one for aluminum basically we're going to grind the side relief angle the end relief angle and the side rake angle okay so let's start out with the side cutting edge or the side relief angle for aluminum that needs to be 12 degrees as I said before I'm driving this one up a little it's showing on the sheet so keep that in mind that's the need to be a little more of an angle Annette hey we're shooting for 12 degrees C 1 rad here little bit shy even more than four more side gone really tangled in it and what I have suspect that's going to be pretty close yep it looks pretty good and now you're not quite up to the top of the tool bit yet let's just continue at that angle and so it comes right up to the top surface you took about learning the brine to hand reigned high-speed steel like this on the grinder is to be able to put the tool back on the wheel in the same position if you took it off that's just that I learned it still on the way I do it is I touch touch the bottom of tool break in the wheel first and I rock into it and you can feel when it when it lays flat on the wheel okay now I'm flat now just keep grinding and I watch the sparks and I get to the top it's over there they're gonna start to set and go over the top see we're right up to the top now that's how you do that I threats the beside brief angle okay now let's cut the under leaf angle at 8 degree and release angle there's no in cutting edge angle it's just 90 degrees unlike on a lathe tool grip there's just over to a bit square of the wheel and grind a little anything all right let's see how red our melon and degrees we are at about ten on this breath that little bit take point so much of an angle around a little more often the top top put them on the top side with cold in the bottom let's see one right now that's about 8 degrees we're not quite up for the top into a bit so let's take a little more off keep the same angle lots for those starts to sell pop it over the top this will go okay now in that place square let's hit it again there we go got a checker angle good motif agreed so we're good there okay so we have our outside relief angle or interleaf angle next thing I want to do is grind the the side the side rake angle okay just like this and that angle is for a limiter 15 degrees yep address ticking geez so let's let's do that one that's easy for me now you have to get out of the way okay let's see my read on that one you're looking for 15 degrees city they're closed and go keep it okay so now just just bring bring that ground surface right up to the to the cutting edge of the tool bit I have to go past we don't want to you don't want that the cutting edge to drop down below the top of the tool that's that's why I don't use both ways on my tools all my tools if you look across the top of them will be straight across and won't be any dipped here in the cutting edges because there's no where there's no back rake and these head do that is and you can sharpen to over and over again without losing the form of your tool that side rake or get back rake I mean eventually you'll have to cut the end of the tool off at some point and start over again that seems kind of listed the back rate doesn't really pop into anything so I just kind of eliminate it to the price here we go a little bit more okay there's the top you can see that there's the top of my tool okay here's the side there VN if you see all that how they all the angles work together one thing we have to do is put a small radius on the nose I don't like to get too big because if you can get away with a larger radius on aluminum because it's soft if you get too big your abs on steel and they start getting chatter in your cut so I usually keep it down to maybe a 30 second or less 30 second movie on aluminum and movie 1/64 on steel so nose radius is a little tricky especially on of course a wheel like this so I'm just going to kinda bring it around something about like that here we go a little nose radius going there so we're all done grinding now I think what I'm going to do now is we'll go back to the mill put it in the flight cutter and I'll take a stone and I'll stone the side cutting head in the end and misery it's just stone right around it I'll make a nice nice smooth edge for a good cut there's me back for the milk okay so now we have our nicely round cutting tool or tool bit goes in the fly cutter or something like that make sure you get these set screws really tight because the interrupted cut can loosen the tool bit up last thing you want is your tool bit to start moving down on you so that's all there is to grinding a tool bit for the flight cutter now you can see now when we rotate it clockwise this is the top of the tool bit this is your side relief angle this is your end relief angle and should do a nice job let's put it in here and grab a stone and just stone the end of it a little bit should do this to all your all your tools your grind follow the contours of the tool just clean up that cutting edge a little bit and give you a lot nicer finish okay so let's see how it works here's a chunk of aluminum long sleeves off here I'm going to need some power now next thing we need to do is figure out what rpm we should cut same as with any other tool at four times the cutting speed divided by the diameter formula find out on my reference page as well so the diameter in this case it varies with a flight cutter because it depends on how you put the tool bit in but this one looks like it's going to be about two and a quarter inches outside diameter so cutting speed for aluminum is 500 four times that's two thousand divided by two and a quarter see where that leaves us here 2.25 divide leaves us about 888 rpm I like to go a little faster with a fly cutter it doesn't heat up like an anvil so it can take a little higher speed without destroying the cutting edge so let's run this in about a thousand rpm it's about there three wearing glasses with the flight cutter because it throws chips everywhere I don't need zoom in a little bit can see what's going on better it's a great indicator using a pipe cutter gives you the opportunity to make sure your heads isn't Ram real easy to see when your head step out of the line it's not perfect making a little potato we won't get this bra size pattern that you see here and you'll end up with ridges between between cuts so you know if it's trimmed right you shouldn't be able to feel any any ridge between your two passes because you can't see that Kenya what's going on here there we go take another pass since I think you missed the first one another five thousands here we go there's a little thing to it I like to fly cutting I like to find mill along the outside of the park that way it doesn't raise a borer you can see the cutters rotating against the outside of the park it won't raise the bar on this end or the other direction then the cutter is going to lift material off the park and wind up with an iceberg no big deal but it's just little things that add up you know unless you have to deal with deburring apart so now you can see that nice crosshatch pattern so that means my head's in tram there's no Ridge between the two cuts and made a pretty nice pretty nice-looking cut okay it looks like we're just about ready to lose battery so let me go grab another battery pack then we'll take a pass on some steel see what the difference is okay for steel we have to recalculate the RPM I'm going to use a piece of mild steel so that's about 100 surface feet per minute stay to 500 so 4 times the cutting speed would be 400 divided by 2 and 1/4 that gives us 177 rpm then we'll bump it up to a little bit to about 2 to 250 give that a shot here's an old rusty piece of steel I found on the shelf I have no idea what it is it's probably mild steel let's see how it cuts this tool bits were ground for aluminum so it has a little bit too much side rake Steele should have I mean a little bit too much side relief 12 degrees instead of 10 that will make a big difference on this and tool life will be reduced a little bit because the sharper angle like that it doesn't carry heat away as fast so your your cutting edge will heat up but this will work fine for demonstration purposes here so we're going to shoot for 200 or so rpm a dog there a bit different huh drop it down to again start to touch you want to be a little careful when you're cutting rusty piece of steel like this because rust is really hard so if you take a really thin cut on here and it's cutting rust the whole pass it's going to dull your tool pretty fast same with cast iron you want to get down below that crust in your first pass so let's let's take it down maybe 15,000 and get underneath that and crust okay going dollar to a bet come pretty well with the chips are silver they're not coming off blue or anything so cutting seas would feed rates a little fast want to take a finish that let's try one slow X feed rate down a bit let's finish roughing this out when will paper I'll finish pass out we see how much of a difference the different materials make on rpm 200 rpm versus 2,000 rpm right mm what we won before rocks lorry on aluminum okay all right not quite as pretty as the aluminum hood so see if we can't get a little better surface finish now it was a rough cut finish gotta speed this up to about 2500 or so it will slow the feed down take off about 5,000 see that what's up to make a much nicer finish their chips are still coming off silver there's no color at all come so we can speed it up even more both the speed and the speed a lot of requests for a video on how to calculate feed rates well it's kind of difficult on the mill like this because it's continuously variable P is that valid a lathe we have you can set it for a certain specific video this is Jedediah 1/2 once again the blue just go bye-bye Pia ruffcut we take as much as you can and steal anyway without chips turn color too much savor the finish tightly run them up you can get away with this it's going to bury by Machine you know the nice rigid machine like this you can get away with a lot higher feed rate than we can on like a bench top Miller's like that so it's kind of something you learn from experience all right so anyway let's saw the basic pointers on how to use the fly cutter I'm not sure what I'm going to do next I'll stop and think about it if it's requests and see what see if you guys been asking for and that's what we're good for just I'll see you next time you

Channel: Toms Techniques

Views: 408,175

Rating: 4.8693681 out of 5

Keywords: machining, machinist, processes, techniques, how to, turning, milling, lathe, mill, threading, thread cutting, South Bend, Logan, Clausing, Delta, Sheldon, Atlas, Bridgeport, Starrett, Lufkin, Mitutoyo, instructional, tutorial, educational, metal, metalworking, shop, machinery, tubalcain, millwork, facing, drilling, grinding, grinder, Harrison, Hardinge, flt cutter, fly cutting, tool grinding

Id: -sLHcFanDpg

Length: 27min 39sec (1659 seconds)

Published: Mon Mar 17 2014