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05-23-2011, 07:44 PM #1
Face Mill Rrecommendations for Aluminum
Gentle readers, I'm in need of about a 4" face mill for use in aluminum. Good looking surface finish will be important, big time material removal will not.
What should I be looking for? Will round inserts be the way to go?
05-23-2011, 08:06 PM #2
Don't over think it.
A 45 degree lead with square (SEHT or similar) inserts leave a great finish. We use Sumitomo WEX face and end mills. No complaints.
05-23-2011, 08:30 PM #3
Mitsubishi has probably some of the best face mills & grades out there - ASX445, AXD4000, AXD7000 & more. Call cust. svc 800-523-0800 to find out who's your rep.
05-23-2011, 09:34 PM #4
Holy Cow! Two responses in and nobody has mentioned Ex Kenna's ripper mill???
Well lets get that out of the way! 4inch ripper mill with polished aluminum specific inserts kick ass! I have 3 inch for plowing. Then amazingly after moving cubes of material it leaves a great finish. I am sure the above responses are good ones, but if you wanted to stereotype the forum you would have a fair bet that aluminum is being moved with Kurtis' (exkenna) ripper mill run on a mari tool holder, in none other then a sharp SV 2412 VMC.
Good night all!
05-23-2011, 09:36 PM #5
Iscar E90AL series cutters with IC28 APCR inserts, either 16 or 22 mm. Great finish, work to a 90° shoulder, lots of sizes, excellent for roughing too. (A lot like a ripper mill)
05-23-2011, 10:38 PM #6
05-23-2011, 11:02 PM #7
05-24-2011, 04:47 AM #8
The Ripper Mill kits are on sale (free inserts).
05-24-2011, 05:01 AM #9
Sorry, forgot to re-size pics.
05-24-2011, 06:09 AM #10
05-24-2011, 06:29 AM #11
Just for s#!ts and giggles....
.........what is the cost of the unit pictured? Without taper of course.
05-24-2011, 08:19 AM #12
Here is the 2" Mitsubishi BXD:
YouTube - ‪Fore Precision Works IRS Diff cover‬‏
The full slotting cut on the outside was full width, 0.2" DOC, and 200ipm. The next cut was dynamic facing at 40% stepover and 600 ipm. Nice and smooth...no drama.
IMO, exkenna's Ripper runs a little smoother than the BXD
05-24-2011, 09:00 AM #13
05-24-2011, 09:04 AM #14
I have exactly the same issue - surface milling 4" wide aluminum with good finish. We are getting ripples currently, and the unit we are using uses inserts we can't identify.
We have to cover a 4" in one pass, so I' will need 4.5-5" head with appropriate inserts. Most of the above is Greek to me. That Ripper thing sounds interesting, but I was unable to find a site.
05-24-2011, 09:06 AM #15
05-24-2011, 09:09 AM #16
Thanks for the link. 2" max won't work for me.
I like that vendor though, bookmarked for next order.
05-24-2011, 09:37 AM #17
We bought a Maritool 90 degree rectangular insert face mill for facing thousands of glass filled nylon parts. After that job was done, I have been using it for aluminum and it makes a pretty finish. I'm no expert on this, but I thought I would toss Maritool's hat in the ring.
Indexable Tooling - MariTool
05-24-2011, 10:55 AM #18
A) I like the 45* mills a lot. They leave super finishes, but you kant go to a shoulder. They are for full decking only.
B) Ex-Kenna's tool looks exactly like a Mitsubishi - no?
C) Mits tooling for the units like Kennas pic is on back-order currently doo to the quake. (not that it has enything to doo with Ex-Kennas supply chain. I am talking about Mits in particular.
We have one job where we use the Mits like above, simply b/c of the small corner tip. Makes it a low feed/Ra tool, but we have a non-rigid part ap, and the Kennametal like it had too much wiper (?) and created too much chatter/bad finish. Went back to the Mits - as much as I hate the import...
Think Snow Eh!
05-24-2011, 03:17 PM #19
05-24-2011, 03:32 PM #20
Ripper mill kit prices:
End mill version
1.00" 2-flute w/20 inserts $240.00
1.25" 2-flute w/20 inserts $245.00
Face mill version
2" 4-flute w/30 inserts $360.00
3" 5-flute w/30 inserts $385.00
4" 6-flute w/30 inserts $410.00
The Ripper Mill and the Mits BXD are very similar except mine has two pegs in the insert pocket that keep the insert from trying to rotate at high rpm/feed rates. Considering that a quality cutter can easily exceed $100 per inch of diameter this is a smoking good deal. The inserts are usually about $13.00 each so you're basically getting them for free. There are probably 60 guys on this board using these and I've only had one return. I don't make a habit of pushing tools on the message board but this tool is such a money maker.
Another tool to consider is the Shear Hog marketed by AB Tools.
I hear really good things about the Shear Hog but don't have any personal experience with it. Lots of guys here on the board using it as well.