Milling 20 mm 30 harden shaft

mirage100

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I got a 20mm 30 hardened rod linear motion shaft that I need to mill a 1/4 inch slot in. It need to be about 1/4 deep and about 2 feet long. Do y'all think I can do this with a 1/4 carbide 2 flute bit. What speed should I use doing it? This is on a manual mill machine. Thank you for a help. Mirage
 
Linear motion rods are Thomson rods most of the time and they can be milled . 4 flute carbide works fine . I make all of our roller shafts out of the stuff in here , it is tough but definately do-able with carbide .
 
How fast should I turn it and how deep of a cut can I make, I got a 2 flute and 4 flute coming. which one would be better?
 
Can anyone help me with this. I am new to carbide tooling and hard material. Got to cut a 1/4 slot about 1/4 deep about 16 inches long. I got some jacks to go under the ends of the rod.
 
Generally a 2 flute will be better for slotting. Personally I would start very light and adjust feeds and speeds by sound and feel.
Your setup will most likely affect what speeds and feeds are correct.
You should be able to find some info on the endmill what chipload it wants, that should give you something to start with.
 
That what I have been doing. Real light and slow . like 0.015 . I have been spending it around 2 thousand RPM. Maybe I am missing something. My pocket machinist hand book leaves out a lot of info.
 
2 or 3 flute will be ideal, but if you want a 1/4" slot you'll need to use a smaller diameter end mill than 1/4". 3/16 or 7/32 would work well as end mills always get pushed to one side when milling a slot so you need to leave room for a clean up to final dimension.
 
That what I have been doing. Real light and slow . like 0.015 . I have been spending it around 2 thousand RPM. Maybe I am missing something. My pocket machinist hand book leaves out a lot of info.
I'm not sure if I understand. Is those settings not working or what do you need help with?

I usually use this page for a quick rough estimate:

Calculating with tool steel(rather use harder than softer steel for the calcs) I get around 3k rpm and 4 ipm using a 3/16" carbide endmill.
If you have a rigid machine and tolerance isn't tight then you'd need to run the 1/4" at 2.3k rpm and 4ipm.
This is for 2 flute endmills.
You can feed almost twice as much with a 4 flute but at the cost of chip clearing which might bite you in the end as the slot fills up. :grin:

Carbide can usually run quite hot(much hotter than HSS tools) but to hot and you will probably dull your endmills.
Best way to reduce heat is either by cooling(not sure if carbide endmills are as sensitive to this as carbide inserts are) or reducing feeds and speeds.
If you reduce your feeds too much relative to your speeds you will start rubbing your endmill rather than cutting, thus increasing heat A LOT, so these need to work together as you adjust your numbers.

The whole speeds&feeds thing is very sensitive to what machine you have.
A big sturdy mill will have no problems with high numbers whilst they may prove catastrophic on a smaller and less rigid mill.
 
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