We have ramped up on a project that has 3/4" MDF veneer with cut outs, drilled holes and area clears in 4" squares .875" deep, as well as drill and cut outs of 13 ply birch. I guess we're going though more sheet stock than I realized and have experienced some stalling even with cut depths at .375 with 2 passes to cut out the shapes.
we're running at 140 to 160IPM at 15,000 to 16000 rpm on a 5HP spindle and PRT w/ascension controls/G code tool path.
We have used both compression and 2 flute onsrud 3/8" diameter bits for these 2 operations trying to extend compression as long as possible for cut out edges.
My question is what are you guys used to as far as bit life before replacing or sharpening?
I guess we've gone through 10 to 15 sheets of each and this end mill is shot with the compression also struggling.
Any guidelines or experience with volume and preventative sharpening or replacements are appreciated.
Thanks