Face Mill- Least Stress into Part

[cincy k]

What types of face mills or inserted cutters put the least amount of stress back into a part. 

 

I have a 2" x 20" long piece of titanium that has a very thin cross section. We are currently using a 2.5" 45 deg lead face mill to face the 2 x 20 surface in one pass. The part seems to want to curl like a pringle or twist after we take a finish pass on the face. The back side of the part, facing down, is hollowed out significantly and the face we are taking material off of is very thin. 

 

Any particular style of tool or brand?

[Rstewart]

That's just the nature of what your attempting...

 

Use an Endmill If you want to put less force on the part.  If this is being done in a Vise it's wise to face, unclamp (clean any chips and shavings away), then lightly place back in the vise to finish skim the part.

 

I just got done doing similar parts in the VMC last week, That process isn't the fastest but the parts were Flat!

 

Hope you left enough material for rough and finish face....

[cincy k]

I am wondering if taking it all in one pass would be better with the part being titanium. It seems the light depth of cut is almost rubbing the part to death. Anyone seen similar results?

[Rstewart]

double post

[Matthew Hajicek - Singularity]

Shear hog?

 

http://www.abtoolsinc.com/prod/shear-hogs-shell-mill

[Guest MTB Technical Services]

What types of face mills or inserted cutters put the least amount of stress back into a part. 

 

I have a 2" x 20" long piece of titanium that has a very thin cross section. We are currently using a 2.5" 45 deg lead face mill to face the 2 x 20 surface in one pass. The part seems to want to curl like a pringle or twist after we take a finish pass on the face. The back side of the part, facing down, is hollowed out significantly and the face we are taking material off of is very thin. 

 

Any particular style of tool or brand?

 

Normally you would want a highly positive cutting edge and a high-helix.

 

However, a Face-mill is the wrong tool for your application.

 

You should try using a single edge fly cutter.

Your application is the perfect application for a fly cutting finish pass.

Very little part stress because of the limited engagement for finish passes.

 

Very popular on Manual and CNC Knee Mills.

Skip to 3:23

[Guest]

Fly cut or multi passes with a small diameter e/m are your best options. Flycut being THE best.

[cincy k]

I'll have to give fly cutting a shot... Never really considered it.

[Josh Kinney -Elite Engineering]

This is the best finish facemill I've ever used. 0.003"-0.005"DOC . Absolutely stunning surface finish and flatness. Can spin to the moon also...

 

http://ecat.ingersoll-imc.com/ecat/ProductSeriesDetails.aspx?ID=16364

[Sticky]

This is the best finish facemill I've ever used. 0.003"-0.005"DOC . Absolutely stunning surface finish and flatness. Can spin to the moon also...

 

http://ecat.ingersoll-imc.com/ecat/ProductSeriesDetails.aspx?ID=16364

 

Looks like it has a large wiper on the insert. What kind of feed per tooth do you do on that thing?

[Josh Kinney -Elite Engineering]

I ran one in Ti-6AL at 200SFM- 0.015"FPT with multiple interrupted cuts and got a Surface finish of 6 all day every day......

[cincy k]

The large wiper flat concerns me. It seems on a finicky thin part it would put stress back into the part and cause more warping issues. What you think?

[Josh Kinney -Elite Engineering]

I would call Ingersoll. They seem to know their s..... I don't see it being an issue. The insert curls the chip upward, the wiper stabilizes the material and insert, not necessarily creating downward pressure.

[gcode]

I'd try a button cutter with hi shear inserts

[THEE THAINZ™]

If you go with a button cutter I would try Sandvik or Ingersoll first. Walters does not leave the quality of surface finish as the other 2.

[specv]

Looks like it has a large wiper on the insert. What kind of feed per tooth do you do on that thing?

We have this cutter as well, its not a flat insert, so its not really a wiper its a very large radius, so large its hard to even tell its a radius. They do put a large amount of down pressure on the parts though.