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Milling & Metalworking Demo Videos

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Special Milling Application Methods

Long-Reach Profile Milling

Constant ramping with a 90-degree shoulder mill is a great technique for easy, efficient long-reach profiling with good surface finishes – even in the roughing cut.

Check out this demo for a peek at this approach using an EDGE² DSS series shell mill.

3D Milling Tips

3D milling involves a variety of tools and tool paths. In less than 5 minutes, this video demonstrates three different 3D shapes, what tools DAPRA recommends for machining and some suggestions for tool path generation for each.

Watch the video.

Radial Chip Thinning to Maximize Feed Rate

If you’re milling at less than 50% of your cutting tool diameter, you can minimize your cycle time – and maximize productivity – by properly adjusting your programmed feed per tooth.

Find out how to leverage radial chip thinning.

Deep, High-Feed Ramping Beats High-Efficiency Milling

This quick contour milling demo illustrates how you can match the metal removal rates of high-efficiency milling with a solid carbide end mill – and save significant money on tooling – by ramping with an indexable high-feed tool.

Check out the advantages of high-feed ramping over high-efficiency milling.

High-Feed Ramp with a Button Cutter, Plunge Finish with Bull Nose

In this detailed instructional video (16 min 45 sec), we look at some unexpectedly efficient options for mold core roughing and finishing.

Have you considered that a button cutter might actually be a great choice for high-feed mold core ramping? We also compare options for finishing the part, comparing bull nose to ball nose cutters and waterline profiling to plunge finishing.

Check out these interesting methods for ramping up your profitability.

How to roughing and finsh a mold insert chase pocket — Roughing & Finishing a Mold Insert Chase Pocket

A solid approach to quickly and accurately milling a deep chase pocket can be a big money-maker for mold shops. Here, we look at a good option for roughing, semi-finishing and finishing the walls and floor of a deep, straight-walled mold insert pocket.

Check out a detailed instructional video or just the live cutting footage.

High-Feed Ramping for Outside Profile Contour Milling

Detailed instructional video (11 min 14 sec) comparing three methods for outside profile contour milling. See how to program each method, compare cycle times, and view demo footage of high-feed ramping on a Haas 40-taper VM2.

Traditional 2D step-down milling
High-efficiency/dynamic milling with a solid carbide end mill
High-feed ramping with an indexable milling tool

See how high-feed ramping measures up.

Roughing comparison: high-feed ramping vs. high-efficiency milling — Roughing Comparison: High-Feed Ramping vs. High-Efficiency Milling

Detailed instructional video (15 min 42 sec) comparing high-feed ramping to high-efficiency/dynamic milling in a typical pocketing application.

Dynamic milling may be all the rage right now, but in many cases high-feed ramping with an indexable milling tool can be a more efficient and flexible solution.

Check out the comparison, including both a high-feed end mill and shell mill.

High-feed ramping and plunge finishing for 30-50% cycle time reduction on tapered or deep walls — High-Feed Ramping & Plunge Finishing for 30-50% Cycle Time Reduction on Tapered or Deep Walls

This detailed instructional video (16 min 32 sec) shows you how to take advantage of plunge finishing utilizing the diameter of a tool, rather than the corner radius of a tool, to dictate the stepover needed to achieve a certain scallop height. By using plunge finishing, you can save 30% to 50% of the cycle time thanks to much larger stepovers.

Check out this simple, effective approach to finishing tapered walls and deep, straight walls.

High-efficiency milling vs. high-feed contour ramping — High-Efficiency Milling vs. High-Feed Contour Ramping

Compare cycle time and tooling cost for three approaches to machining a 1" deep x 3.5" wide x 6" long pocket in 4140PH (28 Rc):

High-efficiency milling – 1/2" solid carbide end mill

Double-pass high-feed ramping – 1" indexable end mill

Single-pass high-feed ramping – 2" indexable end mill

Watch the video and read more about this application.

High-efficiency milling of 6061 ALU with helical roughing end mills — High-Efficiency Milling of 6061 ALU with Helical Roughing End Mills

Dynamic/volume milling with indexable tooling rather than solid carbide end mills.

3/4" dia. Helical Roughing End Mill

6061 aluminum

Pocketing routine

.900" depth

Total cycle time: 5 min. 30 sec.

Watch the video and read more about this application.

Dynamic milling 1018 steel with indexable tooling — Dynamic Milling 1018 Steel with Helical Roughing End Mills

Indexable helical roughing end mills are a great alternative for dynamic/volume milling.

3/4" dia. Helical Roughing End Mill

1018 steel block

Pocket & outside contour

.850" depth

Total cycle time: 4 min. 17 sec.

Watch the video and read more about this application.

Profile Milling: Constant Profile Ramping vs. Standard Z-Level Profiling

Constant profile ramping is a much more effective approach than conventional Z-level profiling. Watch side-by-side as a Dapra 1” end mill (50 IPM / .100" DOC) using constant ramp profile outpaces a traditional 1° helix entry and Z-level rough by more than 50%.

Watch the video.