Try making the cut by doing it in several passes, stepping down 0.500 on each pass. I have actually relieved the end mill above 0.5 inch so it only cuts with with that.
I am cutting 6061, 2.6 long side cut. Using 3. LOC steel titantium mill.
I'm Taking .005 side cut, Mill chatters and anything over 900 rpm and I have to run 30IPM.
The finish is constant but not smooth.
How do you do a cut like this. What tool.
Rob
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Try making the cut by doing it in several passes, stepping down 0.500 on each pass. I have actually relieved the end mill above 0.5 inch so it only cuts with with that.
Jim Dawson
Sandy, Oregon, USA
The problem seems to be that you are not getting a perfect surface by making a full depth cut.
Here are a couple of pictures of a piece I did a while back. 1/2 inch 4 Flute, HSS endmill (from China), 0.020 left to finish, 0.25 DOC, continuous spiral down, don't remember the feed & speed, material = 4150
And here is the finished surface, no step down lines, and smooth as a baby's bottom.
Can't hurt anything to give it a try
EDIT: Here is a gear case out of 6061, 2 inches deep, done the same way as above, same result. Just out of the dishwasher.
Jim Dawson
Sandy, Oregon, USA
I see. Great idea. I'll try it. Thanks much.