Slotting

[megaman]

What in your experience is the fastest way to remove material . I have slots that are 1" wide and 1.5 inches deep. I have tried an Iscar high feed cutter and Iscar and kennametal variable flute end mills. I am looking at using peel mill with a 1/2 inch or 5/8 em . Any feedback is welcome.

[Chris Rizzo]

What's the material? I'd maybe try the 1/2" and do it in one depth cut. Check the database in my sig below, also may want to read this post regarding peel and cutters close to slot size.

[megaman]

4340 and 4130

[NOTW Programmer]

I have used dynamic mill on 4130 at 1000SFM and .004IPT, this yielded 7640RPM, 122IPM with .025WOC. The manufacturer's chart went all the way up to 1700SFM which yielded 13000RPM, 364IPM with .025WOC; our machine is too old to handle that. The width is not an issue but the depth recommended is 2xD which in our case it was 1/2" Varimill.

[ReDEyZZ]

We do a similar application, Can you use a U-drill and punch 1" holes at both ends of the slot(for easy entry and exit) then use a 1" solid carbide Vari-mill style e-mill and take the rest out in 2 passes. 3/4" DOC should work fine. If tolerances are an issue, use a 15/16" U-drill and a 3/4" vari-mill.

[Goldorak]

Iscar's feed mill should be able to get the job done easily....

 

use a 3/4 cutter and ramp down to 1.5 deep using only air to clear the chip

[jeff]

If it were me, I would take a bullnose and ramp the contour to depth leaving .003 stock on the sides, then finish with a 1/2" or 5/8" endmill