Ab Tools/tormach Shear Hog Inserted End Mill

mikey

mikey

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I've been looking for a roughing end mill for use in aluminum. I have standard HSS and cobalt 3 flute roughing end mills but it takes a lot of cutting to rough a 3" X 6" block of 6061 3/16" deep while leaving a 3/16" ledge on one end. Anyway, I think an inserted carbide tool is what I'm looking for.

AB Tools makes the Shear Hog and it looks promising. They also make one for Tormach that works with their TTS system:

http://www.tormach.com/store/index.php?app=ecom&ns=catshow&ref=TTS_SHEAR_HOG

The problem I see with it is that it is intended mainly for use in high speed applications and my RF-31 mill can only get up to 2500rpm at the moment. Once I have a VFD installed (future project) I can try to overspeed the motor but getting 6K is probably not in the cards.

What I want to know is if any of you own this tool and if so, what are your cutting conditions (feed, speed, depth of cut)? What do you think of the tool in terms of finish and how well does it cut to a shoulder? Will it work at lower speeds (2500 rpm max)?

This tool costs $220.00 and each insert is almost $19.00 each! Before I spend that kind of money on a tool that will only cut one kind of material in a hobby shop I would like more info. I emailed AB Tools and got no response. I'm waiting to hear from Tormach and will report what I find here.
 
I'm no expert, but I'm pretty sure it's perfectly OK to run such a cutter at lower speeds. They advertise the maximum RPM so that production shops will know how fast they can make chips and get product out the door. About the only problem I've heard of with running carbide insert tooling too slowly is when cutting steel.

In addition, with a manual mill such as yours, which probably doesn't have high flow flood coolant capabilities, you'd be hard pressed to keep the chips cleared if you ran at production speeds and feeds.
 
mikey said:
I emailed AB Tools and got no response. I'm waiting to hear from Tormach and will report what I find here.
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I can't give you any insight as to the tool in question. However, when I spend serious money I expect to be taken seriously. And to me $239.00 for an end mill is serious money. And I would tend to think, "If they don't respond to a sales inquiry, what will they do with a customer service problem?"
 
There are several Shear Hog You Tube videoes on the net. Here's one posted by an end user that speaks highly of the product.


Tom S.
 
hman said:
I'm no expert, but I'm pretty sure it's perfectly OK to run such a cutter at lower speeds. They advertise the maximum RPM so that production shops will know how fast they can make chips and get product out the door. About the only problem I've heard of with running carbide insert tooling too slowly is when cutting steel.

In addition, with a manual mill such as yours, which probably doesn't have high flow flood coolant capabilities, you'd be hard pressed to keep the chips cleared if you ran at production speeds and feeds.
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You're right, John, I would probably opt to use a vortex gun if I ran at high speeds. I may wind up buying a mini-cooling gun to try anyway, just to see how it works.

I have no doubts that the Shear Hog will cut the material, and I'm not concerned with metal removal rates as I'm just making stuff for myself and can slow down. I guess what is giving me pause is whether or not I want to invest almost 250 bucks to find out how well the tool works in older mills at mortal speeds. I was sort of hoping someone already took the leap. It may turn out that I'll have to do it and report it here.
 
Charles Spencer said:
I can't give you any insight as to the tool in question. However, when I spend serious money I expect to be taken seriously. And to me $239.00 for an end mill is serious money. And I would tend to think, "If they don't respond to a sales inquiry, what will they do with a customer service problem?"
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Yeah, the same thing occurred to me. In today's business climate communication with your client base is key to success and I must admit I'm surprised by their lack of responsiveness.
 
TomS said:
There are several Shear Hog You Tube videoes on the net. Here's one posted by an end user that speaks highly of the product.


Tom S.
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Thanks, Tom. I've seen all the videos and it looks great, doesn't it? The problem is that he's cutting everything at 6K+, which I can't duplicate. I have an old mill that, like me, can't keep up with the new stuff anymore.
 
hman said:
I'm no expert, but I'm pretty sure it's perfectly OK to run such a cutter at lower speeds.
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John, that is absolutely correct. But....you have to adjust the feed speed to match the cutter speed so the chip load stays in a reasonable range. Too little feed and the cutter is rubbing, not cutting. Too much feed and the chips are too thick and your machine is bouncing around.
 
Charles Spencer said:
I would expect NYC CNC to speak highly of his Tormach products:


"Come see the “behind the scenes” from the NYC CNC YouTube channel, meet fellow machinists and makers and enjoy a few metalworking challenges and games!

We’re grateful to have a number of sponsors coming, including Tormach,"

https://nyccnc.eventsmart.com/events/nyc-cnc-2016-open-house/

http://www.tormach.com/NYCCNC-John-Saunders-Story.html#.V9WQ1zVECUk
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Yeah, but I think he got jazzed about the Shear Hog first and based on his experience with it, Tormach approached AB Tools about making it to fit the TTS system they have. Mr. Saunders strikes me as a guy who would have the integrity to rave honestly about stuff that works, regardless of who makes it. That he is in the Tormach camp is, however, very clear.

I like this young man. I like that he found his niche, loves what he is doing and has fit his his business approach into the high tech world we live in. More of our young people should be chasing dreams like him.
 
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