Not happy with my finish with 8ipm using a 3/4 HSS endmill using max rpm1250. Looking to try 3" shell mill next. Suggestions on DOC and IPM and stepover would be apreciated.
If I want a nice finish on 6061 I'd use a flycutter for the final cuts. A piece of HSS sharpened with a generous nose radius in the flycutter, kerosene or WD40 over the part to stop chip welding. Your RPM is fine - I'd use 800+ rpm with a 2" dia cutter and take off 10 thou or less for the final pass. I'd reduce the feed rate though - I'd go for about 2 ipm.
With the flycutter you con do the whole width in one pass - depending on the part's dimensions of course.
With machine off Brought 3/4 4 flute endmill tip up to the work gently up to make contact. Moved cutter of the side. Set spindle to 1250rpm and table to 5ipm.
Finish had visual swirls but nothing you could feel with fingers.
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