[fizzissist]

Hey, Fizzy, do you think we can rule out resonance here?

-Jim Hart

Whenever I've gotten into long parts like this, resonance has been an issue, and it comes and goes sometimes dependent on where the tool is on the part. ...and that excludes the pleasure a long tool can take in resonating without adequate loading...which kills inserts.

So in answer, nope.

[ctate2000]

I did not read all of the posts, forgive me if this has been said.

Cuting speed and chip load are too high, run 1550 and feed 12 ipm. That is 300SFM and .004 per flute. If you want to go faster get more flutes in the cut. A three flute tool will produce 18 ipm. Going to a 1 inch dia four flute and keeping the same cutting parameters would still only produce 18 IPM because the RPM drops off as the diameter increases.

Just my thoughts

[awilliams684]

I think I have it nailed! A 2.5" 45 degree 5fl face mill handles most of the material removal, then a 2.5" 90 degree 5fl to come in and shapes the corners. The 45 degree lead angle was the ticket, there is minimal vibration even on very aggressive cuts. I have the spindle load up to 85% during roughing with that tool and its smooth as butter, I made more chips in an hour today than I have in the last week messing with this damn project! :cheers:

[PixMan]

Wow, you got those cutters fast and put them right to work.

I figured you'd be OK once you got a lot more carbide doing the work. I wouldn't have wagered that the 45º lead angle milling cutter would have been of much benefit because of how little wide, flat area you have to mill. But I'm glad it worked out as well as it did.

Are you using the VP15TF grade for finishing now? Is that working better?

[fizzissist]

I think I have it nailed! A 2.5" 45 degree 5fl face mill handles most of the material removal, then a 2.5" 90 degree 5fl to come in and shapes the corners. The 45 degree lead angle was the ticket, there is minimal vibration even on very aggressive cuts. I have the spindle load up to 85% during roughing with that tool and its smooth as butter, I made more chips in an hour today than I have in the last week messing with this damn project! :cheers:

Glad it's up and running!!!

...I didn't believe in the the 45deg cutters either until I had time to play with them...seemed like the harder I pushed them the better things got.
One big factor could be simply that one cutting force vector is a downward with the 45, while a 90 gives you basically only a side component.

[epmtool]

I think you may have been better off with a good solid carbide variable helix. Did some testing awhile back side milling 316L SS for fun and a 3/8 hanita varimill at 300 sfm, .005ipr 16 ipm, .415 doc, ae .25, cut 210 minutes and removed 333 cubic inches at 1.6 CI a minute. Filled the chip pan on a mazak 510, cut smooth as butter.

[awilliams684]

heres a video of the 45 degree face mill roughing the part were 1 cycle involves 4 16" passes and we completed 50 cycles before having to re-index inserts today.

[nomedia="http://www.youtube.com/watch?v=fs2QvjhW-jU"]YouTube - IMG 0100[/nomedia]

Thanks to everyone who offered help!