Quote:
Originally Posted by RoboChair
I meant to say that the Hass has not had a 100% success rate(works basically every time), not that it can't do it. Part of the issue there is to make a #25 chain sprocket you need to use a 1/8" endmill or smaller and the max spindle speed on the Hass is 7500 rpm when I should be running said endmill at 15000 rpm. So you have to turn the feed down. Also our 1/8" endmill is set in it's tool holder with just over 1" of stickout for clearance reasons with the parts we make and tool deflection doesn't help.
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I would suggest:
Get a split point drill smaller than 1/8" and peck drill around the perimeter leaving a margin smaller than 1/16" for the final break out. Drill straight down so deflection is less an issue. Then when you cut out you'll have less material to engage the end mill dragging it in different vectors as you cut the sprocket parallel to the machine deck.
This could be a little complicated to setup in CAM software. I would suggest doing the drill pass as one operation, then I assume your Haas has an ATC, change for the end mills and complete the cut out.
Also there are Haas spindles faster than 7,500RPM. The price you pay for ignoring the speeds and feeds is really the tool life and as the tool wears you pay for that in quality of cut. Disengaging the some of the cutter would likely increase the tool life at a less than perfect feed and speed.
Best of luck with it - I am sure this operation is within the capability of whatever Haas you have I've done it before.