Quality Indexable Face Milling Shell Mill Recommendations

[erikmannie]

I have never bought a shell mill because I don’t understand how one connects to an R8 arbor. That is, I wouldn’t know which R8 arbor to buy to mount to a given shell mill.

My milling machines are both R8. I am still taking a break from buying Chinese tooling, even though those are much less expensive.

I will usually be face milling carbon steel/alloy steel/SS with 48k-90k psi tensile strength. 1” cutting diameter would be the minimum, & 2” would be wide enough for my purposes. I guess I could go up to 2 1/2” cutting diameter.

I have been using 3/4” diameter, 4-flute el cheapo end mills for this, & it takes too long. I have also chipped the end mills, usually on an interrupted cut. A fly cutter has way too wide of a cutting diameter, & takes even longer.

I also chip carbide inserts doing much the same thing (e.g. facing SS) on my lathe, but I don’t mind switching out an insert. I *do* mind chipping an end mill. I have never tried a carbide end mill or used an end mill holder. I want to use an R8 arbor & an indexable face milling cutting tool.

I know that I could buy a carbide end mill or non-indexable shell mill, but I really prefer carbide inserts.

Does anybody want to recommend a Kennametal, Sandvik, or other quality indexable shell mill (or face milling cutting tool) with a cutting diameter of 1 to 2”, together with a quality R8 arbor?

 

[erikmannie]

I would also be open to using a quality (e.g. Toolmex) R8 end mill holder & a carbide end mill.

I would choose a stubby end mill because I only face mill up to 1/4” of material. I never plunge.

Even a stubby end mill is needlessly long.

 

[davidpbest]

You didn't say whether you needed to cut to a square shoulder or not, but I have some suggestions to share. If you're interested in a 2" or larger face mill, read the attached. I have five of these face mills in different sizes and that take both insert types discussed, and they have been beyond my expectations. I think they are terrific value. I mate those face mills with precision R8 arbors made by Sowa that are available from Suncoast Tools.

I have tried several other types including Shars and been disappointed in the precision alignment of the insert pockets. Have a look at this test I did a couple years ago.

If you want more of a conventional indexable end mill, I have an Iscar 1" that I love. It takes APKT or APMT inserts which are available in a variety of grades for various material types. You can see it in action in the Shars video test at about 4:00 in the timeline.

This is what it looks like - I bought this used on eBay and have really put it through the wringer. It's a 3/4" Shank with 1" cutting diameter and takes 4 inserts:



The designation for this Iscar is E90A and they are available in several diameters from 0.375 upward. There are a few listed as new open box, and some used on eBay.

This is the current production model on MSC: https://www.mscdirect.com/product/details/60841103

I can put you in touch with an excellent independent tool rep with 35 years experience if you want - just message me (not chat, but message).

Hope this helps.

David

 

[erikmannie]

You didn't say whether you needed to cut to a square shoulder or not, but I have some suggestions to share. If you're interested in a 2" or larger face mill, read the attached. I have five of these face mills in different sizes and that take both insert types discussed, and they have been beyond my expectations. I think they are terrific value. I mate those face mills with precision R8 arbors made by Sowa that are available from Suncoast Tools.

I have tried several other types including Shars and been disappointed in the precision alignment of the insert pockets. Have a look at this test I did a couple years ago.

If you want more of a conventional indexable end mill, I have an Iscar 1" that I love. It takes APKT or APMT inserts which are available in a variety of grades for various material types. You can see it in action in the Shars video test at about 4:00 in the timeline.

This is what it looks like - I bought this used on eBay and have really put it through the wringer. It's a 3/4" Shank with 1" cutting diameter and takes 4 inserts:

View attachment 408052

The designation for this Iscar is E90A and they are available in several diameters from 0.375 upward. There are a few listed as new open box, and some used on eBay.

This is the current production model on MSC: https://www.mscdirect.com/product/details/60841103

I can put you in touch with an excellent independent tool rep with 35 years experience if you want - just message me (not chat, but message).

Hope this helps.

David

To date, I have never needed to cut a square shoulder. I am just milling a top surface to be flat.

I really like that Iscar with a 1 inch cutting diameter in the 3/4” shank. I could put that in the 3/4” R8 collet that I already own.

EDIT: I see on the Iscar website that it requires an end mill holder. That is not a problem for me.

 

[davidpbest]

To date, I have never needed to cut a square shoulder. I am just milling a top surface to be flat.

I really like that Iscar with a 1 inch cutting diameter in the 3/4” shank. I could put that in the 3/4” R8 collet that I already own.

Watch it in action in this video at 4:00 in the timeline cutting 304 stainless. It's a great all-round indexable end mill IMO.

 

[erikmannie]

Watch it in action in this video at 4:00 in the timeline cutting 304 stainless. It's a great all-round indexable end mill IMO.

I will check that out now.

 

[jwmelvin]

For a face mill, people often recommend the Glacern FM45, which now comes in an integral-shank version. https://www.glacern.com/fm45

And Maritiol makes another that people like, but will require a separate arbor. https://www.maritool.com/Indexable-Tooling-45°-Square-Insert-Shell-Mill/c50_110/index.html

Those are both the 45° style, for facing but no cutting to a square shoulder. I’m likely to get a Glacern integral-shank soon.

 

[Batmanacw]

If you are doing simple facing I would suggest the SEHT / SEKT1204 insert type face mills. It is staggering how much less noise and impact these cutters have on the part and the mill itself. Much less pounding. Much less side force and flex in the mill head. The 20⁰ rake angle is really impressive.

I have a 2" and a 1.25". I might buy a 1" as well.



The apkt insert type face mills hammered the ever loving crap out of my mills. I really hated them until I tried them on Aluminum at high rpm. Now aluminum is all I use them on unless I need to cut to a shoulder. I have a 4 flute 1.5" and a 2 flute 1".

 

[LeeG]

There is a promotion ending Tuesday for the Kennametal Dodeka Mini cutter. for $249 - there are 10 different models from 2" - 3" diameter. The deal includes 10 carbide inserts - the cutter holds 5. Here is the one I ordered.

https://www.mscdirect.com/product/details/11651429?rItem=11651429

This is the R8 holder I ordered to go with it.

https://www.mscdirect.com/product/details/02910370

I just got mine yesterday so cannot say for sure how good it is, but I've had good experience with Kennametal stuff in the past.

 

[MrWhoopee]

If you are doing simple facing I would suggest the SEHT / SEKT1204 insert type face mills. It is staggering how much less noise and impact these cutters have on the part and the mill itself. Much less pounding. Much less side force and flex in the mill head. The 20⁰ rake angle is really impressive.

The apkt insert type face mills hammered the ever loving crap out of my mills.

^^^^This^^^^

I've had the same experience. I bought an APKT style 2" face mill on an R8-fmb22 shank. I was not impressed with the way it cut steel. On a similar recommendation I got one for using the SEHT/SEKT inserts. Much better! And there are 4 edges per insert instead of 2.