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Roughing End Mill Wonder

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  • Roughing End Mill Wonder

    What a wonder this cutter turns out to be. I have not used one for a long time. I'm working on a job which requires a fine finish so I decided to rough out the bulk and flycut the last fine finish. Since I had a lot of parts to cut by hand in a Bridgeport style mill, I experimented a bit. I was surprised at the depth of cut possible and at how well it cut lightly supported items.

    More wonder. I'm wondering what other uses and tricks I'm missing out on that some of you may have already discovered.
    .

  • #2
    Sometimes known as a "Corn cob" cutter - think of General Douglas MacArthur and his "corn cob" pipe that he smoked:

    http://upload.wikimedia.org/wikipedi...hur_Manila.jpg

    http://en.wikipedia.org/wiki/General_Douglas_MacArthur

    But those cutters which work very well can be pigs to sharpen correctly and keep the outer face/form.

    http://www.google.com.au/search?q=ro...w=1920&bih=884

    http://www.google.com.au/#hl=en&tbo=...pw.r_qf.&cad=b
    Last edited by oldtiffie; 11-15-2012, 08:36 PM.

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    • #3
      Agreed, Im amazed how well rougher end mills work. They look funny, but damn when you see them eat metal.. and feel how smooth your machine is running.. Well, Its not so much smooth, because your going to just push the machine to eat more metal then it ever has before.. but its not the nasty THWANK THWANK THWANK sound of pushing too much steel, its more of a nicer chrunkchrunkchrunk, like its chewing up the steel and spiting it out instead of beating on it.

      Steel looks a little chewed up too But not as bad as you might think from the look of the endmill, don't have to leave much for the finishing pass.

      One of the few endmills I bothered to pay good money to get a name brand cobalt HSS one. (Don't bother with carbide, You'll chip it. Cobalt HSS are near indestructable as long as you don't pit it against anything really nasty)
      Play Brutal Nature, Black Moons free to play highly realistic voxel sandbox game.

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      • #4
        Originally posted by oldtiffie View Post
        Sometimes known as a "Corn cob" cutter - think of General Douglas MacArthur and his "corn cob" pipe that he smoked:

        http://upload.wikimedia.org/wikipedi...hur_Manila.jpg

        http://en.wikipedia.org/wiki/General_Douglas_MacArthur

        But those cutters which work very well can be pigs to sharpen correctly and keep the outer face/form.

        http://www.google.com.au/search?q=ro...w=1920&bih=884

        http://www.google.com.au/#hl=en&tbo=...pw.r_qf.&cad=b
        You have to re-flute them to sharpen.
        We have a cut-of disk mounted on a pedistal grinder.
        So wery carefuly i can dress up the rake angle. This lets the end mill las a little longer.
        Also this method does not affect diameter much.
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        • #5
          Yep Z-D.

          That's about the only way to sharpen them short of having a CNC-ed T&C grinder - as Evan has with his excellent self/home-made CNC mill.

          It might be a stretch for some who seem to avoid manual sharpening of tools and want (need?) special jigs and baldor grinders etc.

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