[wilson248]

Hi Everyone, I am looking for some suggestions or common practices while using face mills, specifically when cutting excess material from the second operation. I currently am working with 3" Walter Valenite 3 insert cutter (Milling Inserts | MSCDirect.com).

My situation is that during the second op, I am cutting of ~0.165" of excess and I have alright luck with depth of cut ~0.065-0.08", but my ears are taking a beating when there is a thin flap of material reverberating as the cutter passes. My intuition tells me to slow it down (feed and speed) and take a deeper cut to minimize multiple passes.

Thanks

[AARONT]

Sometimes i'll go over to a band saw and trim those pieces off or try to get rid of them in the first op. You can also take your profile cut a little deeper than it needs to be and come in with a deeper depth of cut on the face mill to get underneath the thin flap.