So, we have a small VMC (Sharp 2414) in place for doing small volume R&D/prototyping work. Our parts often require use of cast aluminum tooling plate, for stability in the finished part. We are currently running a part from 2" thk x ~8" x ~10" cast plate, starts out at about 23 lbs, finished weighs a bit less than 4 lbs. Lots of material being removed with 3/4" 2-flute carbide endmill, typically 1/2"-5/8" DOC, stepover maybe .5-.6 X diameter. Programmed speed 6K RPM. Final depth of pockets is anywhere from 1" to about 1.7".
Cutter life for the end mills seems short, going from nice-looking part without much burr to a pretty ratty-looking burred edge in 2 parts, total time per part maybe a bit over an hour for rough-out, and interim handling and chip management activity. These endmills are Ultra brand, 45 helix for aluminum.
Anyway, looking for suggestions for highly durable endmills, or insert tools to consider for significantly better lifetime. Thanks --
Cutter life for the end mills seems short, going from nice-looking part without much burr to a pretty ratty-looking burred edge in 2 parts, total time per part maybe a bit over an hour for rough-out, and interim handling and chip management activity. These endmills are Ultra brand, 45 helix for aluminum.
Anyway, looking for suggestions for highly durable endmills, or insert tools to consider for significantly better lifetime. Thanks --