Problem- 2024 T3 plate

[rwild]

I am having warping issues while machining .125" thick 2024-T3 alluminum. It is potato chipping as bad as 7075. I am removing .05". I started off with HSM contouring with a 3/8 dia. ball nose. 10000 RPM at 150 IPM and .01" step over with bad results. I then tried face milling with an indexable to remove .04" before contouring, and the face mill also warped the material. Any one have a solution to the warping, and is T3 that much different than T6? T6 does not seem to warp at all.

[Cruiser]

rwild,
The plate is rolled out and this aligns the grain structure and creates stresses in the plate which are equal so the plate stays flat till you remove the stress from one side and it relieves the stress. This makes it curl, so you may need to clamp and peal one side then flip it over and repeat to keep it balanced out. But of course you will need enough thickness to achieve this. You could relieve the tension with heat but that would defile the T3 condition. Best bet is to peal both sides with a nice sharp cutter, holding it as flat as possible while cutting it. Then after it is relieved continue with making your part hoping for the best. It may still not be perfectly flat when you are done.
Good luck
Don