wide, deep cut question

[fatboy55]

Hello everyone,

I have my manual IH mill all set up and cutting great. Orignal motor. So far I'm very happy.

I'm cutting some 1x2 inch bars of 6061. I need to cut 1/2 inch deep into almost the full 2 inch width. Then a notch on the opposite side from where the left over 2 inch section is left standing. The bars are 3 and 6 feet long.

_
l l
l l__________
l l_
l_____________l

This is close to what the profile looks like from the side.

I've made one with standard end mills, 3/8 and 1/2 but it took too long. The notch at the right end was fast and easy but milling down the 1 3/4 inch wide horizontal plateau was time comsuming.

Aaron suggests a 6 flute 1 inch wide end mill. Before I went out and bought one I thought it might be wise to get the cnczone opinion.

How would you all handle this tooling problem, a few passes with insert tooling covering the full width of my cut or something deeper with less width???

I'll need to make a good number of these bars over the next year so the tool does not have to be very cheap.

Thanks for the help everyone

[fatboy55]

The text image got a bit messed up. Right after the first long horizontal line theres a little bracket l_ that should be moved all the way to the right to form a notch at that end.

Jeff

[fatboy55]

forget this, wrong forum. Sorry