I think aluminum is the worst material to use during the learning phase because that big mill will zip right through it. (Squirt WD40 on it when cutting aluminum.) Like you, my mill is rather healthy (2HP yours looks larger). Without a doubt high speed steel is the best for me on the price/performance curve. I have (practically) every kind of material in popular end mills on the market for guys like us. Now you can look at the speed chart on your mill and know what cutters it is designed to run best and what materials it will perform best on. Even with a backgear, you may only get slow enough to run a 1-1 1/2" cutter at the proper speed. a 1" HSS endmill needs to run at 125rpm in stainless. This is probably more in your mill's speed range. 1500rpm for a 3/32 endmill in stainless, or 3000 for carbide. Stainless and titanium, you cut the speed in half. if you have no blind corners or hard turns to make. A large diam horizontal milling cutter can be run at a much faster surface speed and is a LOT stronger than an endmill. Thsi is one place a horizontal mill is far superior to a vertical mill. HSS steel is cheaper and will work better at lower speeds than carbide, which will chip and break easily at low speed. Now a 3/32 HSS endmill would be fine at 12,000rpm.īet that got your attention, eh? That is why most mills just don't run fast enough to do extremely fine work in aluminum with carbide tools. About 24,000rpm would be ideal for a 3/32 carbide endmill in aluminum. If you are running that same endmill in aluminum, you need to quadruple your speed for steel. You can experiement and try higher speeds, just watch for sparks and back off if you see them. Carbide can be pushed at least twice as fast as HSS. 6000 being a good place to start in mild steel with a 3/32 HSS endmill. Now, you if are running carbide, at least double that speed. Also works the other way, 1" is 250rpm, so 3/4" is 375rpm. This is a bit on the slow side (about 70fpm), but you won't burn up HSS endmills at that speed. Ive read everything from " Suppose you were ride a bike 5 mph and your leg is the mill bit and suppose you foot toches the ground w/ 10lbs of force. What if it was a 1/2" bit under the same circumstances. Now for this same question lets say what would it be for alum, SS, tool steel. What speed (rpm I guess) would I have my bit running. Lets say I have a 3/32 end mill (carbide) and Im milling a slot. Now first off I have no formal training and I know you guys get that alot and I have done my searchs and I cant find what Im looking for so If I could pose a question to you guys in layman terms could someone try to explain it in layman terms? Ive found several charts but w/out training most of it is greek to me. My largest end mill in the sherline was a 3/16, now I can go up to 1" so needless to say Im way out of my element but the water feels pretty good so I want to swim alittle more! My problem is Ive just went from the smallest to the largest. First off ive had a sherline mini mill and lathe for a while now which I have sold and bought a full size mill (bridge port clone)
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