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I could use some experienced guidance here. I’m new to all of this and found myself needing a facemill. I have a step pulley bridgeport so I got myself a 45 degree facemill and while it produces good finishes, even taking very light cuts .001-.005 it sounds absolutely terrible! Like it sounds like it’s smacking the metal instead of cutting it. It’s a touch over 3 inch diameter so perhaps it’s a bit too big? Or possibly s crappy cutter. I did get it off Amazon but the reviews were all stellar. If I take any deeper cuts the sound is so bad I’m nervous to even let it continue…I have taken .100 deep cuts with HSS end mills no problem so just wondering if anyone has had similar experiences. I know this is limited info lol so I csn provide more as needed.
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You don’t say what size or how many inserts, but moving over so more than one tooth is in the work at the same time will help.I cut it off twice; it's still too short
Oregon, USA -
Oops sorry, you did say it was a little over 3”I cut it off twice; it's still too short
Oregon, USAComment
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A 3" would have 4 to 6 inserts, and that 45 degree lead in should give smoother cutting. Maybe the inserts are the wrong grade, or the workpiece is tough. I would not go more than 0.015" depth with steel, but the power is half what a Bridgeport has. Maybe the speed needs adjusting to find the sweet spot.Comment
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What type of inserts are used in your face mill? Rake angle makes a big difference.Comment
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I have a 80 mm diameter 45 degree face mill from Glacern and I love it on my vertical mill. It takes six SEHT1204 inserts and the trick is to have at least one insert cutting all the time. If you mill very narrow part, it may not happen, but then you are using a wrong tool for the job.
The last time I used it on 1045 steel with about .100" depth of cut and it was very smooth cutting.Comment
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It has a 5 insert cutter. It doesn’t specify what material it’s best suited for but I tested it on a piece of steel I had laying around that’s wider than the cutter and it still sounded quite abusive to my poor bridgeport head haha. I played around with several speeds ranging from slow to near max rpm. A thing more than 3 thou deep sounds detrimental to the well being of my spindle bearings. I will post a link to the cutter here shortly…maybe one if you will see something I am missing.Comment
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Also just to clarify a bit more, my head is trammed in both axis to within a couple of tenths.Comment
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A 3 inch face mill is pretty large for a Bridgeport in my opinion. You're not going to be hogging with it. Which insert is the face mill using? Also the actual grade of that insert should be based on the material being machined.Mike
Central Ohio, USAComment
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Maybe your bearings have lost their preload. How old is the machine? Have the spindle bearings ever been serviced? Here is about what a machine of that ilk with decent spindle bearings should sound like. This is a .100" depth of cut in 4140 Q&T, 2" diameter cutter.
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Probably klacking on the back gears like mine does with a fly cutter.Comment
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It definitely was, but I repaired the splined hub that was worn. She runs quiet as a mouse now. I need to look more into these mystery inserts. Or try a smaller cutter.Comment
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Post a few pictures of the face mill or an Amazon link to it. That will help a lot.
Also put a mill in the spindle and check the runout of the cutting edges - axial and radial. It should be within a few thou to assure all inserts are cutting.Comment
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480 RPM with 10 IPM feed should be a good starting point.Comment
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