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Cheap Chinese face mill?

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mksj

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#31
Let’s come back to this, is there a way to adjust one tooth up a thou or so without grinding the insert?
Not really, the inserts also have a coating and are formed with specific tolerances. If you are looking for inserts I would recommend Iscar, Kennametal, Sandvik, Korloy, etc. Unfortunately most of the inserts from China are probably fake, I usually buy from US or EU vendors and only from usually tool surplus suppliers that do not sell everything else that is also made in China. Just too much junk, and the probably why you are having the problems you are seeing. Bad inserts, will cut, but not very well and do not last. Assuming these are APKT/APGT/APMT 1604 then consider the following:
For Steel ISCAR APKT 1604PDR-76 IC928 https://www.ebay.com/itm/10-pcs-ISCAR-APKT-1604PDR-76-IC928/322992042447
For Aluminum Korloy APKT1604PDFR-MA H01 https://www.ebay.com/itm/10pcs-APKT1604PDFR-MA-H01-Carbide-Milling-Inserts-For-Aluminum/162826768705
They are also sold by Glacern under the FM90 link below.

Sometimes one is better off getting something like a Shar's or better yet Glacern cutting head with inserts. At the end of the day, you get much better tolerances and cutting performance for not to much more spend. The other factor that scares me big time is poor hardware and soft screws. One of those goes with an insert, it could cause some serious damage. I also have had better luck buying new old stock or lightly used cutter heads from the same brands mentioned above, I can easily shave a thousandth cleanly off of an aluminum block with a mirror finish. One cutter head that is setup for aluminum has 4 cutting surfaces per insert, so you get a lot of mileage out of them, another has 8 cutting surfaces setup for steel. Also have an APKT 2" head with 6 inserts. When machining aluminum you want uncoated polished carbide, usually a cutter with a forward cant like the FM45.

http://www.shars.com/products/index...lling/2-1-2-45-degree-face-mill-seht-insert-1
http://www.shars.com/products/index...e-milling/3-45-degree-face-mill-seht-insert-1
https://www.glacern.com/fm45
https://www.glacern.com/fm90
 

T Bredehoft

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#32
How about shimming the others down? I had to set some (we called them ) catheads, 10 inches long and 14 in diameter with a number of inserts on the face, in order to get them all the same we routinely put up to .005 shims under the low ones. These were for the first rough cut on the OD face of full sized Ford, Chevy and Chrysler disc brakes. The spindles these were mounted on had roller bearings 42" diameter.
 

Hukshawn

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#33
Thanks for the info, guys. I think I may go and talk to the guys at my local industrial supplier and see what I can get.
 

Technical Ted

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#34

Hukshawn

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#35
I have a bunch of accusize tools. Their quality is about the same. Some good, some crusty. They’re local to me, actually. About 45 mins away.
 

4gsr

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#36
Let’s come back to this, is there a way to adjust one tooth up a thou or so without grinding the insert?
Going up, no. Now you could place a piece of shim stock behind the insert to get it up where you want it. If you want to machine the pocket a little, I would set up in a rotary table, one with compound tilt, so you can match up the angles as close as you can get it. Do so by using a DTI and indicate the insert pocket in both directions. Once done use a sharp endmill and kiss the side of the pocket, just enough that it cleans up. Apply a little cutting oil to the surface. Your only talking about taking a thousandth or so. Before indexing, set up a height gage with a DTI and touch off on the pocket at some reference point that you would use for each pocket in each location. Once done. Index to the next pocket using the height gage to get the pocket into exact placement. Without moving in X on your mill table take a cut across the back of the pocket in Y. If it cuts, fine, if not, mark it and come back to it later. Go to the next pocket and repeat. If one of the pockets did not cleanup, go back to that pocket and adjust X till it cuts. Then go to all of the other pockets. Once done, lets hope the screws will still hold the insert in the pocket without moving. If too much material is removed the insert screw will not hold the insert in place properly. You only get one chance at doing this. It either works or it doesn't work.

Oops, came into this conversation way too late. Sorry.
 

mattthemuppet2

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#37
I would suggest trying some ground inserts for aluminium (usually have H01 in the designation) like these:
https://www.ebay.com/itm/10pcs-APKT...e=STRK:MEBIDX:IT&_trksid=p2055119.m1438.l2649

or even some APGT inserts
https://www.ebay.com/itm/New-10Pcs-...e=STRK:MEBIDX:IT&_trksid=p2055119.m1438.l2649

ground inserts usually have closer tolerances, which may reduce the tip height variation you're seeing, but more importantly reduce the cutting force. Lower cutting force = more shearing and less bludgeoning of the material which usually gives a better finish. No personal experience with face mills, but the difference between CCMT (molded, like your APKT/ APMT) and CCGT (ground) is like night and day. The ground inserts are a little less robust, but in a home shop they'll still last forever.

However, here's what I'll probably get when I save up the $
https://www.ebay.com/itm/KM12-50-22...e=STRK:MEBIDX:IT&_trksid=p2055119.m1438.l2649

and
https://www.ebay.com/itm/10pcs-SEHT...e=STRK:MEBIDX:IT&_trksid=p2055119.m1438.l2649

the 45deg face mills are supposed to give a much better finish at the cost of not being able to face up to a shoulder. This all from reading however.
 

4gsr

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#38
I have a old school 45 deg lead angle face mill that uses SEK_ style insert that is used with a clamp. Does leave a nice finish!
 

xman_charl

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#39
worked Korean factory, milling x-ray grids

Laugan mill, the cutter, had carbide inserts, think about 12 inserts

inserts could be adjusted within a thou

all carbide inserts where ground at another place

put dial indicator on table, do each cutter

2 set screws for each insert

afters cutting, plates went to x-ray for flatness, cracks, flaws

could not use something like a surface grinder, as plate was
sandwitched, with lead, aluminum, strips

plates where soaked in epoxy, baked, and shipped

base price was about $800 each

when used at hospitals for awhile, plate will develope cracks, do
its replaced

Charl
 
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