looking for a small 45 degree face mill

[Dan_S]

I've been collecting tooling for my new mill and it's time to start figuring out what face mill to get. I know everyone recommends the 2.5" integral shank version from Glacern, but Initially I'd like something in the 1-1/4" to 1-1/2" range that would give me a wider operating window in steel. I'll probably purchase the 2.5" Glacern at a later date and dedicate it to aluminum.


my criteria are:
1. integral R8 or a 3/4" or smaller diameter strait shank
2. odd number of inserts


The only think I have found so far that meets my criteria is this 1-1/2" version from shars, does anyone have this mill? how is the quality?
http://www.shars.com/products/view/20276/112quot_45_Degree_End_Mill_R8_Shank_SEHT_Insert_

Does anyone know of any other make/models that I should consider?

 

[Rbeckett]

Shars branded items are usually fairly decent when it come to quality. One caution I would add is to look closely at what inserts it requires and make sure they are not ridiculously overpriced and readily available. I have seen very similar inserts have a range between them that is unbelievable, so it is definitely worth checking that first. A smaller mill for steel is a good idea especially if you plan to upgrade in the future to a larger dedicated mill for Aluminum. I missed which mill you bought, but if it is one of the small to mid sized mills then a 1.5 inch would be an excellent choice, preferably with the R-8 taper already machined on to the shank, that will allow you to retain as much throat room as possible since you wont be stacking adapters and holders to mount it into your quill.

Bob

 

[Dan_S]

I missed which mill you bought, but if it is one of the small to mid sized mills then a 1.5 inch would be an excellent choice, preferably with the R-8 taper already machined on to the shank, that will allow you to retain as much throat room as possible since you wont be stacking adapters and holders to mount it into your quill.

It's a 1.5hp PM-940.

 

[darkzero]

I have a Glacern FM45 2.5" w/ integral shank. I thought about getting even a 2" but I got a killer deal on the 2.5" so I'm glad I did get the 2.5" as it performs awesome.

For smaller than 2" I decided to go with a 90° cutter so it can mill up to a shoulder. I got a 1" 4 flute APKT indexable mill. I don't really use it for facing as I use the face mill for that (I have inserts for both alumn & steel) but occasionally I do. I figured there was no sense in getting a smaller 45° cutter when I already had one.

 

[Dan_S]

I have a Glacern FM45 2.5" w/ integral shank. I thought about getting even a 2" but I got a killer deal on the 2.5" so I'm glad I did get the 2.5" as it performs awesome.

How does it do in steel? You have a pm45 right?

 

[darkzero]

How does it do in steel? You have a pm45 right?

It does fairly well in steel as far as removing material quick. Yes, I have a PM45. But that's cause it's a 45° which requires less effort on the machine, power wise, rigidity is a different story, but a 2.5" is fine for this size mill & BPs of course.

But I don't get as great of surface finish on steel as I do in aluminum. It may just be me though (speeds/feeds) or my inserts. I get a smoother final finish on steel when I use the aluminum specific inserts.

But I've only faced 1018. When my steel specific inserts are new, they'll leave a nice mirror finish but not for long. I think I may be running it too fast for steel, still need to play with it more for steel. But then again 1018 is not a great material to machine than the other steel alloys.

 

[compsurge]

I have a 3" Glacern on my PM-30. I use it only in aluminum and it's worked very well, even at 0.030" DoC.

Most of Shars is good. I can't recommend some things like their indexable boring bar and 3" boring head set because its adjustment dial is too sloppy for my tastes - it cuts well though. For the money, just get a used Criterion off eBay for around $50.

eBay is a great source for inserts. I just picked up some Mitsubishis for SPK at $39 shipped from China. I bought Korloy SEHW43 inserts (10pk) for $70 shipped last year for the face mill, but they are even cheaper now. They are selling for $170-200 on Glacern's site.

This is a good reference chart to help with understanding inserts: https://www.carbidedepot.com/formulas-insert-d.htm

The notations on the boxes mean a lot too. S P K T N, etc. Does anyone have a quick reference chart that identifies which are which? I know P (steel), M (stainless), K (cast iron), but what is aluminum, brass, etc.?

 

[darkzero]

The notations on the boxes mean a lot too. S P K T N, etc. Does anyone have a quick reference chart that identifies which are which? I know S (steel), P (stainless), K (cast iron), but what is aluminum, brass, etc.?

N would be for aluminum, brass, copper, etc., all non-ferrous metals.

From Sandvik:

ISO P – Steel is the largest material group in the metal cutting area, ranging from unalloyed to high-alloyed material, including steel castings and ferritic and martensitic stainless steels. The machinability is normally good, but
differs a lot depending on material hardness, carbon content, etc.

ISO M – Stainless steels are materials alloyed with a minimum of 12% chromium; other alloys may include nickel and molybdenum. Different conditions, such as ferritic, martensitic, austenitic and austenitic-ferritic (duplex), create a large family. A commonality among all these types is that
the cutting edges are exposed to a great deal of heat, notch wear and built-up edge.

ISO K – Cast iron is, contrary to steel, a short-chipping type of material. Grey cast irons (GCI) and malleable cast irons (MCI) are quite easy to machine, while nodular cast irons (NCI), compact cast irons (CGI) and austempered cast irons (ADI) are more difficult. All cast irons contain SiC, which is very abrasive to the cutting edge.

ISO N – Non-ferrous metals are softer metals, such as aluminum, copper, brass etc. Aluminum with an Si-content of 13% is very abrasive. Generally high cutting speeds and long tool life can be expected for inserts with sharp edges.

ISO S – Heat-Resistant Super Alloys include a great number of high-alloyed iron, nickel, cobalt and titanium based materials. They are sticky, create built-up edge, harden during working (work hardening), and generate heat. They are very similar to the ISO M area but are much more difficult to cut, and reduce the tool life of the insert edges.

ISO H – This group includes steels with a hardness between 45-65 HRc, and also chilled cast iron around 400-600 HB. The hardness makes them all difficult to machine. The materials generate heat during cutting and are very abrasive for the cutting edge.

 

[Dan_S]

I'm pretty good when it comes to insert terminology, and getting a good deal. In the home shop, the issue always seems to be finding the right tool holders. for example I would recommend the 1/2" glance set from grizzly for 8" to 14" lathes. I just picked up a second set so I can have a dedicated set for steel & aluminum.

http://www.grizzly.com/products/Glanze-Turning-Tool-Set-1-2/H5681

Milling indexable tooling is really hard to find for me, as everything is arbor mount, or has weldon shanks of 1' or greater.

 

[compsurge]

Can't thank you from tapatalk mobile. I knew stainless was M and steel was P... Must have typed wrong Ha. Good reference. Thanks a bunch!