Don't use ER or TG for heavy cutting, period. If you want to use them for light finishing cuts, that's fine, but I typically delegate the ER's to drilling and tapping duties.
ER and TG have low radial stiffness and increased TIR under load. If you want to take heavy cuts at high revs, use a milling chuck like those from Lyndex-Nikken or Kaiser/BIG. They're a bit more expensive but are some of the best you can buy. A Lyndex milling chuck will set at .0002" TIR, 4" from the nose of the chuck, at better than 4x the gripping power of an ER or TG.
For smaller tools, an 8º collet system like Lyndex-Nikken VC, LSK or MMC series chucks. Kaiser/BIG has a really good "MegaE Chuck" that uses a similar collet system. It all depends on the kind of accuracy you need, the size of tooling you typically use and the materials you machine in your shop. Either way, the new chucks are good to 3 microns at 4D out. That's about twice as good as a good ER.
From the last aluminum job we ran:
1570 SFM (max RPM), Data Flute ALDH-series 1/2" 3 flute end mill, Nikken milling chuck, 7075-T6 aluminum, .5 adoc, .375 rdoc (120º TEA maintained), 500 in/min, 81 in³
I usually run these and a less expensive – but equally good end mill from Destiny Tool – at .75-1" rdoc on our Makino V33... humming right along and never a pull-out issue. Ti-6Al-4V, with 45 and 60º end mills, no issues.
I should be a Lyndex sales rep...
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