Extra long insert cutter

[dforsythe]

6061 alum

 

I have to cut a pocket approximately 2.0 x 4.0 x 11.25 deep with a full rad on the floor.  ( from the side it would look like a U shape ).  The c/r are .750 with a small flat in between.  Anyone know of a an insert cutter with extensions that could get that deep.  Im thinking a 1.0 or 1.25 high feed mill or inserted ball end mill.  I would like to rgh and fin at the same time.  Add an extension and go deeper…repeat as needed.

[Guest]

What Holder size?

 

CAT50 is doable in 10" reach plus cutter thickness

 

http://www.techniksusa.com/metal/pdcsmcat.htm

[specv]

We use the form master with the screw on style end. You can add extensions to get whatever length you need.

 

http://www.ingersoll-imc.com/en/products/NEW-163-3_Form-Master-Shear.pdf

[dforsythe]

Specv,

 

that is very close to what I need.  I should have mentioned I need a 1.0" ball head to finish the btm section. iscar and seco have something close... but the longest combo I can see is 11.78.  I also looked at millstar.

[specv]

you can add extensions to the holders though to get what you need. just keep screwing them on.

 

http://www.ingersoll-imc.com/en/products/uc/0720_Innofit_Top_On_Toolholders.pdf

[specv]

also check out the Ingersoll Proball, they screw on to the same extensions.

 

http://www.ingersoll-imc.com/en/products/uc/0236_Profile_Mills.pdf

[specv]

Also check out Korloy they are awesome for cutting AL

 

 

http://www.korloy.com/newkorloy/eng/product/product0610.html

 

http://www.korloy.com/newkorloy/eng/product/product0615.html

[Newbeeee™]

We've just done this for a production job as we wanted carbide body and 3tip so we can push hard.

25mm dia carbide rod sparked out centre, turned up (with spigot) end from 'tough steel', brazed in, then end finish turned and finally put up and ground to get some relieve (25mm down to 24.5mm).

It works like a charm, but it is for a repeat running job so worth our effort in doing it.

 

 

Oh, and +1 on korloy. We use their facemills for ally - 40mm dia for everything except the odd job where we use the 60mm.

[dforsythe]

 i ended up going with the seco.  im going to use 3 bodies.  high fee, 90 deg ( for walls ) then the ball.  with inserts and a carbide shank it was under 3k.  not too bad for how deep im going.

[dstryr]

Are you cutting aluminum? I've had good luck with the AB Tool Shear Hog on the smaller shank in a long extended tool holder. The tool dia is like .030 smaller than a long extended holder. That was only 8" deep but worked fine.