Milling a pocket in Aluminum or Steel with clean sharp edges

[macardoso]

For steels, I like to buy endmills from GARR tool. They have really good cutting data available for them and their prices are pretty reasonable for a mid range tool. I like the V4S line of endmills (EDP 50540 for example is a 1/4" endmill performance endmill for steel with a short 3/8" long flute - $20).

GARR TOOL - Product Details

www.garrtool.com

 

[Mercedes107]

Yikes! That looks like a complicated part! What is it for?

Custom AC compressor manifold.

 

[Dabbler]

I used to have surface problems like that when manual milling as well. An old machinist buddy told me to take a first pass on the final dimension, taking only a .002 cut - using the final dimension side of the end mill in the climbing cut dimension. Somehow it works, and there seems to be a much smaller burr which is removable with scotchbright with a wipe or 2.

I hope this helps!

 

[Mercedes107]

I used to have surface problems like that when manual milling as well. An old machinist buddy told me to take a first pass on the final dimension, taking only a .002 cut - using the final dimension side of the end mill in the climbing cut dimension. Somehow it works, and there seems to be a much smaller burr which is removable with scotchbright with a wipe or 2.

I hope this helps!

I did try about 0.006, both conventional and climb, I thought that would be close enough. I will be practicing more when I get some new end mills. For the moment my wife has got the clamp on buying tools.