I have always liked Sherline machines and have had a manual one for a long time so I bought a CNC Sherline mill to do some heavier duty work that my K2 2514 router can not handle. I am disappointed to say that the Sherline can not do the job either, not that it is not a great machine for lighter duty work.
What I am trying to do is machine some 6061 aluminum blocks. I need to do a pocket about 2.5 X 4" and 3/4" deep with odd radii and straights on the sides. I am using an Onsrud 63-624 single flute cutter that is 1/4" diameter with a 1.25" length. Using the recommended 14 IPM at 2800 RPM. Onsrud says I should be able to do full width cuts 1/4" deep at this feed and speed, but I have found that on the Sherline that full width and only .1" deep gives a bunch of chatter and rough edge. .2" deep and taking off only .020" on the side is no better and even if I spend forever making this pocket with light cuts I can't get full depth and take a .005" finish cut around the perimeter without chatter.
I have put the bit in my manual Bridgeport and it can make a full width cut at .25" deep at 14 IPM like it was cutting butter so I am convinced that the Sherline just does not have the rigidity in the column for these cuts. The part is fairly low so the head is not cranked up very high. Machine is new and backlash and gibs are adjusted correctly and there is no play or flex that can be discerned.
With the ton of passes it will take to make this pocket it will take me hours to cut this. I was looking to do parts in 5-10 minutes. Using a smaller cutter will require less rigidity, but still take even longer.
So two questions. Is there something wrong here or are others with the Sherline machines getting the same results?
Next question is what machine would be recommended if I want to spend under 4K and get something rigid enough and a fast enough spindle to make a 1/4 X 1/4 cut at least 15 IPM?