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Serious question, did anyone else run their roughing passes way too fast for years
I ran a 3/4 inch roughing end mill at 3200 RPM for almost 4 years straight on 1018 steel because that is what the guy who trained me ran and I never questioned it. Last month a tool rep stopped by the shop in Garland and watched me run a part, then asked why my inserts were chipping every other cycle. He pulled up the speeds and feeds chart on his phone and my jaw dropped, I was running about 40 percent too fast the entire time. I had been blaming our tooling budget and writing off insert cost as just part of the job when it was my own numbers burning them up. Since I dropped it down to around 1900 RPM my insert life went from maybe 6 parts to over 30 on the same setup. The crazy part is our cycle time barely moved because I was losing so much time on tool changes and scrap. Now I want to go back and check every program I ever wrote at this shop. Anyone else here got humbled by a feeds and speeds chart after years of doing it the same way?
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carter.thea17d ago
I spent my first two years running a chamfer tool so slow I could have hand filed the edge faster, so yeah, I feel this in my soul. The worst part is you trust the guy training you because he has been doing it for 20 years, but nobody ever checks if he learned it right in the first place. Good on you for dropping the RPM instead of just buying more inserts.
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