Indexable Milling vs Solid Carbide

[rgrin]

Found an old 1" Shear Hog in a cabinet that hasn't seen the light of day for probably 10 years.  I chucked it up and ran it and was shocked at how much chipload they want you to push.  Did some prep work that had it running at 12000 rpm - 360 ipm - .2" DOC - .75" WOC -.03"IPT in 7075.  Put the Yasda at only 50% spindle load but peeling around 54 cubic inches off. To compare, dynamic milling aluminum with a 3/4" Rougher, I achieve around 34 cubic inches at 50% spindle load.  Soooo, seemingly I can get more MRR with the right indexable tooling and the right application of it.

This is leading me down a rabbit hole of different indexable cutters and ultimately lead me to the Fullcut series from Big Daishowa.  They appear to be the only ones doing an integral shank Big Plus BT40 tooling and the quote I got for one puts it cheaper than a stand alone Powrgrip holder.  I'm reaching out to sales to confirm and maybe setup some test cuts. 

I'm wondering if certain insert cutters in the right application can they achieve higher MRR than Solid carbide, specifically in lower power machines?

Anyone else go down this hole?  Other tools I should look at?  Maybe I need to take another look at the tooling I am using for Dynamic milling to see if there's something better out there?

[gcode]

One the to keep in mind about integral shank tooling.

When you lose the cutter, you lose it all.

Even if you never have a catastrophic failure, the insert seats and threaded holes will eventually wear out  and the entire unit will need to be replaced.

With a Powergrip holder/inserted endmill you only need to replace the inserted endmill.

One the plus side, it will be more rigid,,,, and you'll never have to worry about an idiot operator

using the wrong tool or sticking it out an extra 2" "just because"

 

edit...  I just wanted to add one comment. 

The quality and value of everything I have ever bought from  Big Daishowa has been outstanding. 

[rgrin]

The quote I got back for the Integral style from Big Daishowa is about half the price of a cylindrical shank insert mill and a Big Daishowa sidelock holder.

 

Actually, looking at prices on holders right now, I'm noticing about a $50-$100 increase across the Powergrip line.  Thats a little concerning.... Must be adjusting due to popular demand