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- Jun 12, 2014
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I recommended the square shoulder Haas because of the deeper cut and higher rate of material removal, but you can also go with a 45 degree shoulder type with the insert seat pocket more vertical as opposed to significantly positive. Also want to look at the number of cutting edges per insert as that will effect time before replacement/costs. You are limited by the rigidity and Hp, but you should be able to spin a 2.5" head w/o difficulty. The 833T (assuming gear head) should have plenty of power due to it's geared head) where the 833TV might have some more difficulty in steel. Aluminum you can definitely dial up both RPM and feed, and benefits from a more positive rake pocket. I was just impressed with the Haas in steel, the finish was great and very little vibration. The arbor for the face mill is a function of the size face mill, I have been using the Sowa shell arbors which are reasonably priced and well made. Please note that you may need to buy a different mounting bolt for the Haas face mills, as they use ones with a smaller bolt head then provided with the arbor. You could also use a rougher like a 3/4 or 7/8" and hog out a lot of material and then come back with a face mill for final finish.
There are a multitude of factors as to how a face mill will perform so one can generalize, but it does not account how an individual face mill will perform and the type of insert used. That being the case, I get very good finishes with all the different face mills I use, and part of this has to do with the design/accuracy of the head and the inserts. There have been a number of issues with some of the generic types having different insert heights with poor finish. I run a 4" face mill for final finishing and the inserts can be setup for either ferrous or non-ferrous materials, since they are positive rake they cannot be flipped, but have 8 cutting edges. DOC is probably limited to around 0.050", this is around 2800 RPM, feed of 10-12 IPM in 7075, mill is 3 Hp and not breaking a sweat. So there are a number of choices, they will all work reasonably well given you are not looking at maximum material removal rates.
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There are a multitude of factors as to how a face mill will perform so one can generalize, but it does not account how an individual face mill will perform and the type of insert used. That being the case, I get very good finishes with all the different face mills I use, and part of this has to do with the design/accuracy of the head and the inserts. There have been a number of issues with some of the generic types having different insert heights with poor finish. I run a 4" face mill for final finishing and the inserts can be setup for either ferrous or non-ferrous materials, since they are positive rake they cannot be flipped, but have 8 cutting edges. DOC is probably limited to around 0.050", this is around 2800 RPM, feed of 10-12 IPM in 7075, mill is 3 Hp and not breaking a sweat. So there are a number of choices, they will all work reasonably well given you are not looking at maximum material removal rates.