The workpiece material: Steel #45,

[shanghongcao]

The workpiece material: Steel #45, similar to JIS S45C, ASTM 1045, 080M46, DIN: C45
Hardness:Normalized, HB220

Job Description:
The top & bottom surface have been pre-surface-ground
To machine 3 holes from the solid blank only!
Hole dia. 50mmH6
Hole dia. 100mmH6
Hole dia. 75mmH6
Surface quality: 1.6

Machine: Vertical Machining Center X=2600mm, Y=600mm, Z=600mm
Control System: Siemens 840D Powerline
Spindle RPM: 0-6000 RPM with internal coolant through spindle
Spindle taper: SK50 DIN 69871A

Basically I would like to interpolate the hole from solid, using one cutter.
The hole 1 to D49.8mm
The hole 2 to D99.8mm
The hole 3 to D74.8mm

Then using a fine boring tool (for example, Kaiser fine boring tool) to bore the three holes to the target size.

Question:
# 1: What kind of fixture is good for this kind of work? Can anyone recommend any clamping fixtures for this kind of work?
#2: The hole interpolation, I wish to have the cutting force as small as possible. The plate thickness is very large and can be easily deformed if the cutting force is too much. What kind of cutter is good to do the interpolation? Can anyone recommend the tools and cutting parameters?

 

[mfgenggear]

shang

how square are the edges to each other & to the bottom & top?
at least one end needs to be square.

what is the volume? this will dictate type of tooling & fixturing.

mfgenggear

 

[TVP]

Synchronous milling, also called climb milling, has lower cutting forces, improved chip formation, and better surface quality. Conventional milling (reverse rotation) has a lifting action on the workpiece that requires more elaborate fixturing. Like mfgenggear said, the exact type of fixturing depends on how many of these things you need to machine.

 

[shanghongcao]

how square are the edges to each other & to the bottom & top? at least one end needs to be square.
I don't know how square it is now. We can get the squares perfectly milled.


what is the volume? this will dictate type of tooling & fixturing.
The volume is not an issue. It is a kind of mass production.