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Milling weld bead

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Djl338

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I’m finishing up a sheet of steel (.25”) that was tig welded and need to remove the bead and get the surface flush. Normally I would use a flap disc, 1” roloc, and conditioning disc. Got to thinking about milling the surface, and was wondering if it’s a good idea. I thought about using a face mill, was wondering if there’s a better endmill choice or just stick with the old method (it’s carbon steel). Trying to get the finish cosmetically perfect.
Thanks
David
 

Karl_T

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I do this all the time. WAY quicker. I use dull/chipped endmills that are mostly wore out for this. leave 5 or 10 thou to finish with a flap disk.
 

Djl338

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Thanks Karl, does it matter of its 2,4 flute center cutting? IM all about way quicker:chunky:
 

Karl_T

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If you got money to burn, use a brand new one inch four flute carbide center cutting. When you hit a hard spot and waste it, don't blame me.

I use out of the dull pile, what ever is in there.
 

Djl338

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Well, no money burning for me. a 1” carbide center cutting end mill is probably more than a semester for my kids college tuition. I’ve got some old stuff to use, thanks for the tip
 

markba633csi

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Karl is right, welds can be tough to mill, and drill

What happened to the likes button on this thread?
 

Djl338

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Gave it a try with a 1/2 center cutting carbide end mill that iI had and , really impressed myself on how well it works, no waves from the normal sanding grinding process, great finish, took a little setup time but well worth it.
Thanks Karl
 

Karl_T

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Hope that was a brand new Hanita variable flute with TiAN coating :)
 

Djl338

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Yup, went to the vault in the sub- basement and broke out the new Hanita :oops:
 

projectnut

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A little over 10 years ago we had a new deck put on the family cottage. When we got the price for the railings I almost had the big one. I decided it would be a good project to build it from scratch. Not being a great welder I cut all the parts to spec and took them over to a friends shop to have him do the welding.

I was pretty happy with the results and loaded the sections into the trailer to transport them to the cottage. I thought it would be a good idea to show them to the wife before painting them. That's when I got a rude awakening. She thought the raw welds looked terrible and suggested I dress them up on the mill.

Two weeks later they were nearly ready for paint. I beveled all 4 surfaces where each stile is connected to the top and bottom rail. The majority of the work was done with a 3/8" ball end mill with the finishing touches completed with a die grinder and deburring disks. In all there was a little over 1,000" of surface to be milled and finished. It only took 2 end mills, but close to 40 deburring disks.DCP00775A.jpg

Raw welds

DCP00777A.jpg

Milling complete, next step polishing

DCP00783A.jpg

Project complete
 

Djl338

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Looks great!, and bet a ton of work but totally worth it
 
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