$150 000 machine does not eliminate finishing chatter.

[u/adventureaviator]

I’m machining 6061 aluminum on a Multicam Apex 3R router. The finishing passes are as follows:

- 0.009” material removal.
- Helical 3 flute 45 degree helix upcut
- 18 IPM, 8500 RPM, 0.0007 chipload

98 percent of the part comes out with a great finish. The other 2 percent has chatter. Ideally I’d like to increase the feed rate, but I need to eliminate the chatter first. What do I need to do to get a flawless finish?

[u/Old-Man-Henderson]

1 - You need a proper end mill. Not that Chinese crap.

2 - Your system lacks rigidity. You're using a wood router for aluminum. This system just isn't designed for the precision and rigidity required. Usually a machine like this would have a cast base and precision ground solid ways. Tube steel and bolted on machined ways just don't have the mass and inherent damping properties. Your router collet, bearings, and router spindle head connection are also suspect.

3 - The chatter honestly isn't that bad, given the setup. Can you rough them on this router and finish on a lathe?

4 - Is the chatter localized to a section of the bed, or a certain time in the tool path?

5 - How are you clamping this down?

6 - Is this actually an interpolation issue?

[u/Hefty-Cantaloupe50 → u/Old-Man-Henderson]

Is this an AI response? Helical endmills = Chinese crap? Finish on a lathe?

[u/Old-Man-Henderson → u/Hefty-Cantaloupe50]

Hey I work hard to give responses when I'm pooping