Recommendation for face mill

[PT Doc]

Using the carbide depot link:
5” cutter diameter, all 8 inserts, 5” WOC, 350 SPM

 

[PT Doc]

Using the carbide depot link:
5” cutter diameter, all 8 inserts, 4” WOC, 350 SPM

 

[Shootymacshootface]

First, I am the farthest thing from a feeds and speeds guru.
I have a 3hp knee mill, and the first face mill I bought was a 3" which works great on almost everything. I noticed that I was using it on a lot of smaller parts and it doesn't run smoothly unless you have several cutters engaged on the work at the same time. I just got a 2" face mill, but haven't used it yet.
I don't think you will have a power issue with a 5hp mill.

 

[PT Doc]

Using the carbide depot link, the number for cubic inches removed are as follows:
Also going on G Morsch’s conversion of 1 cubic inch removal =~1hp.

4” cutter diameter, all 6 inserts, 4” WOC, 350 SPM. -=>4.5 cubic inches. ~4.5hp.

5” cutter diameter, every other insert installed for total of 4 inserts, 5” WOC, 350 SPM. -=>3.0 cubic inches. ~3.0hp

5” cutter diameter, all 8 inserts, 5” WOC, 350 SPM. -=>6.0 cubic inches. ~6hp

5” cutter diameter, all 8 inserts, 4” WOC, 350 SPM. -=>4.8 cubic inches. ~4.8hp

So many numbers, still a bunch of questions. Are interrupted cuts with a face mill less than ideal? For less wide material, a 1” or 1.25” indexable end mill seems like it would be better.

 

[mksj]

The positive rake requires less Hp (FM45) I use a 2.5" in aluminum with no issues and also have a 4" with 7 inserts, I use a 2" for ssteel with an R8 and 3 Hp motor. The calculations or for maximum material removal which is seldom the case as a hobbyist. I would not leave out inserts as it will effect the surface finish. As mentioned I would probably go with a 4" FM45 for softer materials and a a 3 or 4" FM90 for harder materials and shouldering with a heavier mill and 5 Hp. You could get a single arbor. I like the larger head for wider stock, but can also be used on smaller stock. You need accurate head alignment, I get almost mirror surface. I use some air to clear the chips.

 

[PT Doc]

The positive rake requires less Hp (FM45) I use a 2.5" in aluminum with no issues and also have a 4" with 7 inserts, I use a 2" for ssteel with an R8 and 3 Hp motor. The calculations or for maximum material removal which is seldom the case as a hobbyist. I would not leave out inserts as it will effect the surface finish. As mentioned I would probably go with a 4" FM45 for softer materials and a a 3 or 4" FM90 for harder materials and shouldering with a heavier mill and 5 Hp. You could get a single arbor. I like the larger head for wider stock, but can also be used on smaller stock. You need accurate head alignment, I get almost mirror surface. I use some air to clear the chips.

Are interupted cuts an issue for insert durability and surface finish?

 

[mmcmdl]

Are interupted cuts an issue for insert durability and surface finish?

Not at all . It's an insert cutter and always has interrupted cuts ! Not sure how it would have a continuous cut ?

 

[PT Doc]

Not at all . It's an insert cutter and always has interrupted cuts ! Not sure how it would have a continuous cut ?

I didn’t phrase it properly. With a 4” diameter face mill on 2” wide stock, the inserts will engaging the material and then coming off of the part. With a 1.25” indexable end mill on 2” stock, the end mill and inserts would not be coming off the part the same. No?

 

[mmcmdl]

Wouldn't make a difference . An insert on a mill cutter is never fully engaged in a cutting action . It cuts in then 180 degrees it's out . Make sense ? The cutter is still parallel with the bottom cut but not actually cutting .

By the way , I'm an old time Kennemetal and Valenite guy .

I understand what you're saying though ! You're talking about re-entering the workpiece with a larger cutter . With the correct grade carbide this has little to no effect . I believe Valenite V02s were the insert of choice years ago .

I may add , why would anyone use an undersize facemill other lack of HP ? Just adds time to the job !

 

[PT Doc]

Wouldn't make a difference . An insert on a mill cutter is never fully engaged in a cutting action . It cuts in then 180 degrees it's out . Make sense ? The cutter is still parallel with the bottom cut but not actually cutting .

By the way , I'm an old time Kennemetal and Valenite guy .

I understand what you're saying though ! You're talking about re-entering the workpiece with a larger cutter . With the correct grade carbide this has little to no effect . I believe Valenite V02s were the insert of choice years ago .

I may add , why would anyone use an undersize facemill other lack of HP ? Just adds time to the job !

Thank you. Sounds like the the 4” would be a good choice for my 40 taper 5hp machine? Since I will only be getting one face mill initially, do you think the 45* SEHT..... style is the most versatile?

https://www.glacern.com/fm45