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  1. Wait, this is

    Wait, this is <1/2 diameter deep? That makes it pretty weird that you're breaking endmills. Something else must be wrong. Coolant concentration? ALTiN coated endmills?

    Regards.

    Mike
  2. ZrN Coated 3/16 dia 3 Flute High Helix Carbide...

    ZrN Coated 3/16 dia 3 Flute High Helix Carbide Rougher X .500 loc MariTool
  3. Line bore? 48" stroke @ 1.5" is really pushing...

    Line bore? 48" stroke @ 1.5" is really pushing it, but maybe.

    Regards.

    Mike
  4. Don't think you can send attachments through...

    Don't think you can send attachments through messages. Send me an e-mail with your e-mail address.
  5. Sure, if PM allows that attachment. Otherwise...

    Sure, if PM allows that attachment. Otherwise send me an e-mail.

    Regards.

    Mike
  6. 1. Make a new plane such that you are looking...

    1. Make a new plane such that you are looking down the length of the surface
    2. Project the (3D) edges of the surface to some Z value, making a new 2D projection of that 3D surface
    3. Project a...
  7. Replies
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    Carbide, sure, why not? But HSS, cobalt,...

    Carbide, sure, why not? But HSS, cobalt, vanadium, whatever, as long as the hole is the right size. And yes, the hole needs to be the right size!

    Reaming is only necessary if the drill isn't...
  8. Variations in the constituent elements (but still...

    Variations in the constituent elements (but still within the allowed ranges), differences in the thread rolling procedures resulting in more or less work hardening.

    Also the bolts may have been...
  9. Replies
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    Try a bigger drill. Standard drill size for...

    Try a bigger drill. Standard drill size for 5/16"-18 is .255"

    Regards.

    Mike
  10. Replies
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    Update ... It turns out that the actual...

    Update ...

    It turns out that the actual required reach is only~7/8", as there is a ~.350" entry to the first cross bore. So, I can use a 3/16" x 1" reach lollipop, which is a lot less snaky than...
  11. Replies
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    2,346

    I know some folks hate MSC, but I don't have any...

    I know some folks hate MSC, but I don't have any complaints. They stock zillions of form taps, from various makers, coated and uncoated. The 25-50% extra I might spend at MSC is easily offset by the...
  12. Replies
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    2,346

    Not in my experience. I've had TiCN Kennametals...

    Not in my experience. I've had TiCN Kennametals load up whilst running in 6061.

    Regards.

    Mike
  13. Replies
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    You might ask around a bit if you are considering...

    You might ask around a bit if you are considering a new one. I have heard tales of newer PhasePerfects having issues with high-speed spindles. My 2015 355 has been perfect though.

    Regards.

    Mike
  14. Replies
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    2,346

    I've seen Al build-up on TiN and TiCN taps so I...

    I've seen Al build-up on TiN and TiCN taps so I stopped using them and am now just plain bright uncoated.

    Regards.

    Mike
  15. Replies
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    Can't imagine anything 1/4" or smaller slipping...

    Can't imagine anything 1/4" or smaller slipping in a decent ER collet, the tap would just break off.

    Regards.

    Mike
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    Online Metals. I have used Speedy Metals in...

    Online Metals.

    I have used Speedy Metals in the past, but I like Online better.

    Regards.

    Mike
  17. Yes, I cut a chamfer after roughing and before...

    Yes, I cut a chamfer after roughing and before finishing so the boring head should have a gentle entry.

    Regards.

    Mike
  18. 1. I suspect flank wear at first, then chipping...

    1. I suspect flank wear at first, then chipping once things start going sideways. I don't have a microscope so do not know specifically.
    2. Bore size starts going small, then after a couple boring...
  19. These inserts have a very small nose radius so a...

    These inserts have a very small nose radius so a higher feed rate makes a less-nice surface.

    Regards.

    Mike
  20. This is what I will probably do. Regards. ...

    This is what I will probably do.

    Regards.

    Mike
  21. These are the inserts that are supplied by the...

    These are the inserts that are supplied by the place I bought the boring head kit from. These are the only insert I have yet found, that fits these bars. I'm fine to try a carbide insert, but am...
  22. Whisper quiet and a mirror finish, until the edge...

    Whisper quiet and a mirror finish, until the edge starts to break down.

    Regards.
  23. Why do my cermet boring head inserts break down so quickly?

    1018 steel
    1" thick
    .7504" thru bore
    Rough it out to .748" with an endmill

    Brother Speedio S700X1
    Stanny micron boring head
    16mm x 60mm bar
    TPGH09020L TN60 insert (Kyocera cermet)
    2,000 RPM
  24. Replies
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    Yes, that's a long reach with a .117" neck. Might...

    Yes, that's a long reach with a .117" neck. Might work though. Doesn't need to be pretty, just absolutely positively no burrs allowed

    I can do it with a lollipop going down the .386" holes, but...
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    Maybe, but that would be an 8X endmill, and might...

    Maybe, but that would be an 8X endmill, and might cause more issues than it solves.

    Regards.

    Mike
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