Quality Indexable Face Milling Shell Mill Recommendations

[davidpbest]

Just to clarify, APKT type face mills will cut to a square corner, and I use them on aluminum, or when I have to cut to a square shoulder on steel. It does push the rigidity limits of the mill - demo video here in 304 stainless.

Otherwise I prefer the octagon-shaped inserts with the HAAS face mill discussed in the paper I attached to my original post in this thread. The octagon inserts have 8 cutting edges compared to the four on the SEHT/SEKT, and like the SEHT, the inserts are set at a positive rake. That Kennamental promo package mentioned by @LeeG looks like a terrific value if you can deal with a negative rake insert geometry - I hope he posts more about it after some use.

This is the 3" HAAS octagon-style face mill (they come in 2, 2.5, 3 and 4"), and for $130 is a terrific value IMO. The inserts are $90 for a pack of 10, and this SOWA R8 arbor is another $62.

 

[Stonebriar]

I put this on my list David. As usual an excellent article.

 

[Batmanacw]

Just to clarify, APKT type face mills will cut to a square corner, and I use them on aluminum, or when I have to cut to a square shoulder on steel. It does push the rigidity limits of the mill - demo video here in 304 stainless.

Otherwise I prefer the octagon-shaped inserts with the HAAS face mill discussed in the paper I attached to my original post in this thread. The octagon inserts have 8 cutting edges compared to the four on the SEHT/SEKT, and like the SEHT, the inserts are set at a positive rake. That Kennamental promo package mentioned by @LeeG looks like a terrific value if you can deal with a negative rake insert geometry - I hope he posts more about it after some use.

This is the 3" HAAS octagon-style face mill (they come in 2, 2.5, 3 and 4"), and for $130 is a terrific value IMO. The inserts are $90 for a pack of 10, and this SOWA R8 arbor is another $62.

I know the OP doesn't want Chinese stuff but the Lamnia SEKT inserts are really impressive for just over a buck an insert. The Chinese YG SEKT inserts are even better for $3 each. That was a huge attraction for me. It might not be patriotic but it fits my budget.


How does the huge wiper area on the Octagon inserts work out? Is that whiper area flat to the cut surface? Do they require a high feed to avoid rubbing?

 

[jwmelvin]

How does the huge wiper area on the Octagon inserts work out? Is that whiper area flat to the cut surface? Do they require a high feed to avoid rubbing?

I was wondering about the octagon. It seems like the corners would wear, leaving only four usable positions for the insert?

 

[mksj]

Octagon inserts are flat on the bottom, the major limitation is the DOC. In general the face parallel to the work should have minimal wear and the outer angled flute would wear, so you should get 8 cutting edges. Below is an Iscar 4" face mill with octagon inserts, works well for facing, mine is setup for aluminum. There major difference between a better made face mill and the poorer quality ones is the often the milling of the pocket and alignment of the inserts in the pocket. If any of the inserts are not at the same height you will get ridging. Haas, Shar's (?Glacern) and a number of other face mills are made in mainland China, but have better QC/machining and give excellent finished. Many of the newer inserts have complex geometries that improve the cutting performance and durability. Performance wise, I would recommend the Haas face mills as a balance between cost and performance. Iscar, Sandvik, Kennametal, etc. expect to pay 3-4X more for the name unless you can find one on eBay (like I did) or similar at a bargain price. With these brands, you are often locked into expensive proprietary inserts, that can be difficult to source.

Cheap Chinese face mill?

You get what you pay for?! No wayyy!!! Get outta town!! Bought a 2" face mill on fleabay for 20 bucks. It came with 10 inserts. Which, big surprise, have no numbers on them. But the ad lists APMT1604PDER. Anyways. I had to make an R8 arbor for it. That was a good lesson. Took the final cuts on...

www.hobby-machinist.com

I run my 4" Iscar at around 3200-3400 RPM milling 7075 aluminum, with a feed in the 10-12 IPS for a good finish, but can increase the feed for quick material removal. Inserts are polished carbide with a sharp edge, would only be suitable for light surfacing cuts in steel.

 

[Eyerelief]

I run my 4" Iscar at around 3200-3400 RPM milling 7075 aluminum, with a feed in the 10-12 IPS for a good finish

Seems fast. You don't experience any chip welding at those speeds?

 

[erikmannie]

By the time I sat down to make this purchase, I only had a measly $135.

I will have to make do with a 7/8” square endmill & a 7/8” R8 collet (my largest R8 collet on hand was only 3/4”). See details below.

This endmill was $98.31 delivered. I haggled him down $10.00:







The auction description said that this solid carbide endmill lists for $178. I sure would not have paid even close to that!

 

[erikmannie]

Here is the 7/8” R8 collet. It is new. It set me back $36.42 delivered. Hopefully that TIR of .0011” is a typo.



EDIT: Upon further research, I learned that this size Lyndex collet is made in Taiwan:

Lyndex-Nikken Collet, R8, 7/8in 800-056 | Zoro

Order Lyndex-Nikken Collet, R8, 7/8in, 800-056 at Zoro.com. Great prices & free shipping on orders over $50 when you sign in or sign up for an account.

www.zoro.com

I also learned that you are likely get a higher TIR on a larger diameter collet.

 

[mattthemuppet2]

I have piles of Mitsubishi 4 flute 1" indexable endmills and I'm sure I could rustle up some new carbide endmills of similar sizes for alot less money than what that 7/8" one cost you. Send me a PM if you're interested.

 

[mksj]

Seems fast. You don't experience any chip welding at those speeds?

No chip welding at all, you can see the aluminum come off in shreds, chips are about 1/2" long. If I want to improve the finish I use my FogBuster type system. Also it is 7075 which is not as gummy as 6061, I prefer to machine it. I have not had issues with chip welding/build up with any of my face mills, it may also be the profile and the inserts I use.

Lyndex R-8 collets are good, I use them, but you if you look you can find sets for a lot less than you paid. Vertex are also good and cost less.