Large peice of 304 Stainless to mill

[machinedudester]

I have to do a large detailed pocket in a piece of 304 that is 1"x40"x40". I have estimated cutting it with my BDX4000 at 14.0fpm and 1800rpm with doc at .05" a pass and the machine time ends up almost 50 hours. Does anyone have a lot experience machining 304 and can tell me if this is a good approach? I am concerned about the tolling holding up for such a long time. Thanks!

[?Mark]

quote:

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BDX4000

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This cutter is great but for aluminum

I'd reconsider the tooling.

[cobra95kev]

I would consider some type of feedmill, without seeing the part that is about all I can say. You can remove alot of material in a very short period of time with these things, especially if it is a contained pocket and the tool can remain almost fully engaged.

 

Good Luck,

[heavychevy2155]

Are you really going to go 14.0FPM(168ipm)?

[heavychevy2155]

+1000 to the feed mill, but 304 can be a headache. Talk with your tool supplier about different grades of inserts and coatings.

[YoDoug®]

Watch out for warping also. If you are removing a lot of material you may have to do it multiple operations flipping the plate in between to keep it flat.

[Chris Wichlaz @ lpmachine]

how about a mitshibishi 3" ajx cutter. We cut 316 at .050 doc, .025 feed per tooth at approximently 800 rpms which equals 80 ipm. I know we have ran this at 100 ipm in 316 with out any problems, I just can't remember what the spindle speed was at that at that feed rate. We ran dry on a Matsura 630 with a bt40 taper.

 

I hope this helps. I do know the insert life was good we were using a grade vp30rt cutting dry.

 

WHen I get in tommarrow if I can find some of my notes I will post them

[88Matt]

what grade of 304 is it?

[Goldorak]

Niagara elite series end mill are awsome in ss304

 

 

i will try a 2500 rpm (500sfm approx.) .05WOC and .010 to .006 ipt (using thinning factor)thats about 100ipm with a 3/4 rougher (sr420)

 

 

your cutting cycle should be a lot under the 50h

[machinedudester]

So you do not think that the BXD4000 is not a good tool choice? We would have to buy a new cutter or use a carbide end mill, which I am concerned will not hold up long enough. It says it is recomended for stainless and there are stainless grade inserts for it. I have lathed 304 before but not milled it. As far as warping goes, the material will be pre-ground to finish thickness, and the ribbed pocket is all one one side of the part. So I cannot flip the part.

[?Mark]

It'd do well for some shouldering and finishing but not roughing. Those are fairly high positive inserts, and any heavy/interrupted cut will send them flying.

Now, 50hr cut time in this material would be hard to achieve no matter the tool, so you might want to rethink your approach. I'd try different roughing tool and divide your cycle into several steps and so on...

[MIL-TFP-41]

I also doupt the BDX cutter is the way to go....if the part were alum, it would be a no brainer. I also have had good luck with the AJX cutters in stainless.

 

with that big of a pocket....I would expect the part to go into a taco shape after you rough the material. Stainless is not exactally what you would call stable.

[Namliek_J@TheeCircle™]

1" deep pocket that is 40" x 40"?

 

What about plunge milling? We have done some work with plunging 304SS using Kennametal Z-axis tooling and running dry. Removed alot of material in a short amount of time.