Making a 4.25" cut 2.5" deep

[Allumiworks]

Hi guys I have to make this trim piece out of aluminum 4'x6' rect. bar

im pretty much turning it into an H with the cut being 4.25 wide and 2.5 deep

what type of tool would you suggest im thinking maybe like a face mill or fly cutter ... but the fly would have to be designed where the cutting edge was at the furthest point so as not to hit the wall of my part.

I attached a pdf if that helps. and thank you for any advice you can give.

jeremy

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[Jim Dawson]

I assume you mean 4x6 inch aluminum bar as opposed to 4x6 foot. (4'x6')

What machine are you going to use to do this?

An insert type endmill might be the best.

[Allumiworks]

yes sorry i did mean 4"x6"
I am running it on a kia va 50 max spindle speed is 2500 rpm

[Jim Dawson]

With a 2500 RPM spindle this is going to take a while to run. But given your machine, I think about a 2.5 inch carbide insert end/face mill and a trochoidal cutting pattern would make the most sense. Follow the cutter manufacturer recommendations for feed, speed, & DOC. You will have to adjust feed down to keep the correct chip load at your RPM.

[Allumiworks]

thank you