Below are some indicative feeds and speeds for different materials:
Blue Styrofoam (Bluefoam)
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Stock block size: 150x150x100mm/ 6x6x4in Approx. machining time: 1:30h Roughing pass done in two parts indexically (3+2 axis) Tool 6mm 2 Flute Carbide end mill at 15,000RPM, Feed 4000mm/min (157ipm) DOC 6mm (0.236in) Finishing pass done in 5-axis simultaneously Tool 4mm ball end mill Carbide at 15,000RPM Feed 4000mm/min (157ipm), final stepover 0.7mm (0.027in) |
5xMonkey Toolpath: Fusion360 Toolpath:
Tip: To reduce roughing machining time: instead of block of material we removed some of the material on a bandsaw.
Mahogany Hardwood
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Stock block size: 150x150x100mm/ 6x6x4in Approx. machining time: 5h Roughing pass done in two parts indexically (3+2 axis) Tool 6mm 4 Flute carbide end mill at 15,000RPM, Feed 5000mm/min (196ipm) DOC 2mm (0.07in) Finishing pass done in 5-axis simultaneously. Tool 4mm ball end mill Carbide at 15,000RPM Feed 3600mm/min (141ipm) Final stepover 0.5mm (0.02in) |
Front View: Specimen milled from a solid block of wood.
Left: original stock block, centre: Roughing pass, right: Finishing pass.
DuPont Corian® Solid Surface*
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Stock block size: 150x150x100mm/ 6x6x4in Approx. machining time: 5h Roughing pass done in two parts indexically (3+2 axis) Tool 6mm 4 Flute Carbide end mill at 15,000RPM, Feed 5000mm/min (196ipm) DOC 2mm (0.07in) Finishing pass done in 5-axis simultaneously Tool 4mm ball end mill Carbide at 15,000RPM, Feed 3600mm/min (141ipm), final stepover 0.5mm (0.02in) |
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Stock block size: 150x150x100mm/ 6x6x4in Approx. machining time: 8h Roughing pass done in two parts indexically (3+2 axis) Tool 6mm ball end 4 flute Carbide at 15000 RPM, Feed 7000mm/min (275ipm) DOC 4mm (0.157in) Finishing pass done in 5-axis simultaneously Tool 4mm ball end flute Carbide tool at 15000 RPM, Feed 7000mm/min (275ipm), final stepover 0.1mm (0.00394in) |
A model machined out of wax was taken to a foundry where a brass piece was cast through a method of investment casting /lost wax casting. Following which the specimen was polished. Artefacts of the original STL polygon mesh are clearly seen on the surface of the finished piece and aren’t due to a surface finish or machine settings. However, it does show that one should think about how polygons size affects the final resolution of the model. It’s always worth checking the model in a wireframe mode to make sure the mesh resolution is sufficient or switch from Polygons to Nurbs altogether.
Milled Machinable Wax piece and Brass Cast piece next to it.