I have a 3 cutter 2" 45 degree Sandvik face mill. Previously I have used it with no problem, for example 3000 rpm, .1 DOC, full width, 30 ipm.
Today I tried to pocket with it, and managed to stall it with very conservative parameters such as 2400rpm, 6ipm, full width .03 DOC. The problem is when the face mill is making a very shallow ramped entry into the material (.03" over 1 inch). I read the thread which says that the max torque is around 2200 rpm, so I dropped it down to that value. I guess because the face mill is hollow in the middle, when you do a ramped entry, all inserts are cutting all the time, so it's like double full width.
One idea is to make the ramp even more shallow, like .5 degrees. The problem is that it's not easy for me to get Sprutcam to always make exactly the tool paths I want. I don't think it can do a custom form tool for Roughing Waterline, so I can't be sure it's not forgetting to machine out the area in the hollow section of the face mill.
Assuming I can get toolpaths worked out, another idea was to just use the low speed pulley for more torque anyway. I don't need the huge SFM.
I also have a 1" 90 degree insert mill, which doesn't have as much torque requirement. I still have the same concerns about the tool paths, though.
I could just rough out the pocket using a 3/8 end mill too.
Any other suggestions?