Deep fin cutting

[Tranquil]

Hi. We cut 5083 aluminium on a good cnc vertical mill (8000 rpm, 15HP spindle)

Our biggest challenge is cutting fins into the side of the blocks. We normally cut full depth of the block (z up to 40mm) with a 6mm tool (currently a flexible cobalt rougher) in 5mm depth passes. We may cut up to 35mm long (x) cuts, leaving 3mm fins between the 6mm slots. We cut at 8000rpm, between 1000 and 1400 mm/min feed rate

But we suffer tool breaks, and the rougher leaves a poor internal edge of the fins. We use a flood coolant, flushing out the slots

What would you recommend..... We have never yet, tried single flute cutters, but will try anything to get more life from the tools....

We can get as little as 30 minutes of cutting, or up to 20 hours, under same conditions, so we are a little confused?

We use standard ER32 collets (no flat)


I welcome your feedback, and recommendations


Thanks

[txcncman]

Most likely, what you are attempting to do, to the level you are trying to do it, is unnecessary. Maybe you should upload some blueprints as attachments here so that people can possibly give you other ideas.

[dstryr]

Turn it sideways and rough it out with a carbide saw.