Guides-WAM-WAMR-Technical-Data

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WAM & WAMR Technical Data

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WAM Technical Data

ISO Grade Material/Grade SFM Range Application Recommended Starting Parameters
Radial DOC (% of dia) Axial DOC (x of dia) SFM Starting Chip Load Per Tooth
1/8 3/16 1/4 5/16 3/8 1/2 5/8 3/4 1
N Aluminum / Aluminum Alloys <10% Si 800-2000 Full Slotting 100% 1x 800 .0012 .0018 .0025 .0032 .0037 .0050 .0065 .0075 .0100
Heavy HEM* Profile 33% 2x 1200 .0013 .0019 .0027 .0034 .0039 .0053 .0069 .0080 .0100
Med HEM Profile 20% 2x 1800 .0015 .0023 .0031 .0040 .0046 .0063 .0081 .0094 .0120
Lt HEM Profile 10% 3x 2000 .0020 .0030 .0042 .0053 .0062 .0083 .0108 .0125 .0160
UL Lt HEM Profile 5% 4x 2000 .0028 .0041 .0057 .0073 .0085 .0115 .0149 .0172 .0220
Finishing 5% 2x 1000 .0009 .0014 .0019 .0024 .0028 .0038 .0049 .0057 .0070
Aluminum / Aluminum Alloys <10% Si 500-1500 Full Slotting 100% 1x 700 .0010 .0015 .0022 .0028 .0033 .0044 .0061 .0070 .0090
Heavy HEM* Profile 33% 2x 1000 .0011 .0016 .0023 .0030 .0035 .0047 .0065 .0074 .0100
Med HEM Profile 20% 2x 1300 .0013 .0019 .0028 .0035 .0041 .0055 .0076 .0088 .0110
Lt HEM Profile 10% 3x 1400 .0017 .0025 .0037 .0047 .0055 .0073 .0102 .0117 .0150
UL Lt HEM Profile 5% 4x 1500 .0023 .0034 .0050 .0064 .0076 .0101 .0140 .0161 .0210
Finishing 5% 2x 800 .0008 .0011 .0017 .0021 .0025 .0033 .0046 .0053 .0070
Brass / Bronze 500-900 Full Slotting 100% 1x 500 .0015 .0021 .0027 .0031 .0044 .0056 .0071 .0081 .0110
Heavy HEM* Profile 33% 1.75x 600 .0016 .0022 .0029 .0033 .0047 .0059 .0075 .0086 .0110
Med HEM Profile 25% 2x 700 .0019 .0026 .0034 .0039 .0055 .0070 .0089 .0101 .0130
Lt HEM Profile 10% 2.5x 800 .0025 .0035 .0045 .0052 .0073 .0093 .0118 .0135 .0180
UL Lt HEM Profile 5% 3x 900 .0034 .0048 .0062 .0071 .0101 .0128 .0163 .0186 .0250
Finishing 5% 2x 600 .0011 .0016 .0020 .0023 .0033 .0042 .0054 .0061 .0080
Copper / Copper Alloys 700-1000 Full Slotting 100% .75x 500 .0010 .0015 .0022 .0028 .0033 .0044 .0061 .0070 .0090
Heavy HEM* Profile 33% 1.5x 650 .0011 .0016 .0023 .0030 .0035 .0047 .0065 .0074 .0100
Med HEM Profile 25% 2.x 800 .0013 .0019 .0028 .0024 .0041 .0055 .0076 .0088 .0110
Lt HEM Profile 10% 2.5x 900 .0017 .0025 .0037 .0047 .0055 .0073 .0102 .0117 .0150
UL Lt HEM Profile 5% 3x 1000 .0023 .0034 .0050 .0064 .0076 .0101 .0140 .0161 .0210
Finishing 5% 2x 650 .0008 .0011 .0017 .0021 .0025 .0033 .0046 .0053 .0070
Magnesium / Magnesium Alloys 500-900 Full Slotting 100% 1x 500 .0015 .0021 .0027 .0031 .0044 .0056 .0071 .0081 .0110
Heavy HEM* Profile 33% 2x 600 .0016 .0022 .0029 .0033 .0047 .0059 .0075 .0086 .0110
Med HEM Profile 20% 2x 700 .0019 .0026 .0034 .0039 .0055 .0070 .0089 .0101 .0130
Lt HEM Profile 10% 3x 800 .0025 .0035 .0045 .0052 .0073 .0093 .0118 .0135 .0180
UL Lt HEM Profile 5% 4x 900 .0034 .0048 .0062 .0071 .0101 .0128 .0163 .0186 .0250
Finishing 5% 2x 600 .0011 .0016 .0020 .0023 .0033 .0042 .0054 .0061 .0080

Radial Chip Thinning Was Applied To Chip Load Data

Optimizing WAM & WAMR For Machining Conditions

Optimimum WAM/WAMR Settings by Material

  • Unit Power For Aluminum Alloys ≈ 0.33
  • Unit Power For Brass / Bronze Alloys ≈ 0.64
  • Unit Power For Copper Alloys ≈ 1
  • Unit Power For Magnesium Alloys ≈ 0.16

Machine Efficiency % ≈ 0.8 * Motor Horsepower

Machining Formulas

RPM = (3.82 x SFM)/ tool diameter
SFM = RPM x .262 x tool diameter
FEED RATE (in/min) = chipload x # flutes x RPM
Material Removal Rate (in3/min) = Feed Rate x ADoC x RDoC
Feed/Tooth (in) = Feed Rate / (RPM x # Flutes)
Required motor horsepower = feed rate x axial doc x radial doc x unit power x machine efficiency %
Radial Chip Thinning =

WAMR Technical Data

ISO Grade Material/Grade SFM Range Application Recommended Starting Parameters
Radial DOC (% of dia) Axial DOC (x of dia) SFM Starting Chip Load Per Tooth
3/8 1/2 5/8 3/4 1
N Aluminum / Aluminum Alloys <10% Si 800-2000 Full Slotting 100% 1x 800 .0043 .0065 .0074 .0086 .0104
Heavy HEM* Profile 30-40% 1.5x 1200 .0045 .0068 .0078 .0090 .0109
Med HEM Profile 20-25% 2x 1800 .0051 .0078 .0089 .0103 .0125
Lt HEM Profile 8-12% 3x 2000 .0072 .0108 .0123 .0143 .0173
Aluminum / Aluminum Alloys <10% Si 500-1500 Full Slotting 100% 1x 700 .0038 .0059 .0068 .0080 .0094
Heavy HEM* Profile 30-40% 1.5x 1000 .0040 .0062 .0071 .0084 .0099
Med HEM Profile 20-25% 2x 1300 .0045 .0071 .0081 .0096 .0113
Lt HEM Profile 8-12% 3x 1400 .0063 .0098= .0013 .0133 .0157
Brass / Bronze 500-900 Full Slotting 100% .75x 500 .0048 .0069 .0078 .0091 .0110
Heavy HEM* Profile 30-40% 1.5x 600 .0050 .0072 .0082 .0095 .0115
Med HEM Profile 20-25% 2x 700 .0057 .0083 .0093 .0109 .0132
Lt HEM Profile 8-12% 2.5x 800 .0080 .0115 .0130 .0152 .0183
Copper / Copper Alloys 700-1000 Full Slotting 100% .75x 500 .0038 .0059 .0068 .0080 .0094
Heavy HEM* Profile 30-40% 1.5x 650 .0040 .0062 .0071 .0084 .0099
Med HEM Profile 20-25% 2.x 800 .0045 .0071 .0081 .0096 .0113
Lt HEM Profile 8-12% 2.5x 900 .0063 .0098 .0113 .0133 .0157
Magnesium / Magnesium Alloys 500-900 Full Slotting 100% 1x 500 .0048 .0069 .0078 .0091 .0110
Heavy HEM* Profile 30-40% 1.5x 600 .0050 .0072 .0082 .0095 .0115
Med HEM Profile 20-25% 2x 700 .0057 .0083 .0093 .0109 .0132
Lt HEM Profile 8-12% 3x 800 .0080 .0115 .0130 .0152 .0183

*ONX is a proprietary coating developed to reduce friction and improve chip flow.

Programmer's Perspective on WAMR

One of the unintended consequences of 2 to 4 times diameter deep axial High Efficient Milling (HEM) is the creation of "long, stringy chips." These chips do not flush away easily and tend to remain on the work holding and machine tables requiring machine operators to expend extra time clearing them during part change outs.

An aerospace facility that aggressively uses HEM roughing tool path strategies was experiencing this issue on their vertical milling machines and the time saved from HEM milling was being lost clearing matted together chip piles on the work holding and machine table.

This shop was introduced to the WAM Rougher to help increase their metal removal rates, while also eliminating these longer chips. The WAM Rougher is designed to take aggressive feed rates, while also breaking up the chips into shorter segments that can be easily flushed away from the part. The coolant stream carries them to the chip conveyer for quick removal.

The WAM Rougher proved to be a great solution. By design, the WAM Rougher allows light duty vertical and horizontal mills to be more efficient at aggressively cutting material, while solving the chip evacuation and piling problems.

- JOL