Hi Guys,
My question involves getting a smooth surface when using an end mill to cut through a 1” piece of aluminum.
I am starting with a piece of aluminum stock approx. 3 feet long x 2” wide x 1” thick. I want to cut off a section that’s 6” long. When the cut is complete, I want the end to be clean and very smooth. I placed the stock piece in a milling vise and tightened the jaws. Approximately 8” stuck out the side of the vice (just enough clearance for the quill). The piece sticking out was unsupported at its end. I used a ¼” carbide 4 flute end mill to make the cut using multiple passes (.015” per pass). Appropriate table and Z axis were locked each time as was the quill.
When the piece had been cut, the end was not smooth. Under close inspection the end surface looked “wavy” (thought straight). Before taking the piece from the vise I decided to make another pass in hopes to get a far smoother end surface. Feeding slowly, taking a very fine cut from the end (.002”), I passed my cutter along the end surface making the .002” cut. The surface was still rough and without making the cut any deeper, I passed the cutter back and forth several times in attempts to smooth the surface. To some extent I realized a little better surface but not like what I would get if using a surface facing mill cutter.
Is there a trick to getting the surface I desire using the above method and if so, what’s the trick? Am I expecting too much of the method indicated above?
Thanks,
Harold
My question involves getting a smooth surface when using an end mill to cut through a 1” piece of aluminum.
I am starting with a piece of aluminum stock approx. 3 feet long x 2” wide x 1” thick. I want to cut off a section that’s 6” long. When the cut is complete, I want the end to be clean and very smooth. I placed the stock piece in a milling vise and tightened the jaws. Approximately 8” stuck out the side of the vice (just enough clearance for the quill). The piece sticking out was unsupported at its end. I used a ¼” carbide 4 flute end mill to make the cut using multiple passes (.015” per pass). Appropriate table and Z axis were locked each time as was the quill.
When the piece had been cut, the end was not smooth. Under close inspection the end surface looked “wavy” (thought straight). Before taking the piece from the vise I decided to make another pass in hopes to get a far smoother end surface. Feeding slowly, taking a very fine cut from the end (.002”), I passed my cutter along the end surface making the .002” cut. The surface was still rough and without making the cut any deeper, I passed the cutter back and forth several times in attempts to smooth the surface. To some extent I realized a little better surface but not like what I would get if using a surface facing mill cutter.
Is there a trick to getting the surface I desire using the above method and if so, what’s the trick? Am I expecting too much of the method indicated above?
Thanks,
Harold
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