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PSA: I ran the same 6061 part for a year with a 2-flute, then swapped to a 3-flute
The cycle time dropped by almost 15% and the finish got way better. I mean, I should have tried it way sooner but I just stuck with what I knew. Anyone else have a simple tool change that made a huge difference?
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ray3561mo ago
Funny you mention that, @violaramirez. The 6061 vs 7075 thing is a real point though. I think where people mess up is assuming the flute count rule is universal. Like, a 3-flute in 7075 might chatter if your machine isn't rigid enough, but in 6061 it's often the opposite. For aluminum, the extra flute gives you a better finish because the chip load per tooth drops even if you bump up the feed a bit. Sethm46 is dead right about side-by-side tests being the only way to know for sure. I learned that the hard way after wasting a year running a part with a 2-flute that could have been done in half the time with a 3.
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sethm463mo ago
Getting stuck in a tool rut is way too easy. The side-by-side test is the only way to break out of it.
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violaramirez3mo ago
Yeah that "stuck with what I knew" part hits home. We get comfortable with a tool that works okay and just stop looking. I forced myself to test a single-lip drill for deep holes in aluminum last month and it was a total game changer. The chip evacuation was so much cleaner. Sometimes you just gotta buy one new tool and run a side-by-side test. The results usually make the cost worth it.
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