[artracing]

I am cutting 6061, 2.6 long side cut. Using 3. LOC steel titantium mill.
I'm Taking .005 side cut, Mill chatters and anything over 900 rpm and I have to run 30IPM.
The finish is constant but not smooth.
How do you do a cut like this. What tool.

Rob

[Jim Dawson]

Try making the cut by doing it in several passes, stepping down 0.500 on each pass. I have actually relieved the end mill above 0.5 inch so it only cuts with with that.

[artracing]

Try making the cut by doing it in several passes, stepping down 0.500 on each pass. I have actually relieved the end mill above 0.5 inch so it only cuts with with that.

I rough cut that way and leave .005 final wall thickness.
Then the side needs final cut. In one pass to have perfect surface

[Jim Dawson]

The problem seems to be that you are not getting a perfect surface by making a full depth cut.

Here are a couple of pictures of a piece I did a while back. 1/2 inch 4 Flute, HSS endmill (from China), 0.020 left to finish, 0.25 DOC, continuous spiral down, don't remember the feed & speed, material = 4150



And here is the finished surface, no step down lines, and smooth as a baby's bottom.


Can't hurt anything to give it a try

EDIT: Here is a gear case out of 6061, 2 inches deep, done the same way as above, same result. Just out of the dishwasher.

[artracing]

I see. Great idea. I'll try it. Thanks much.