Big high-feed cutter opening an internal pocket in a large block

Oct 17, 2026 Last reply: 13 hours ago 4 Replies
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When this setup is running, a 3-inch Mitsubishi high-feed cutter is opening up an inner cavity in a big A106 block on a Mazak 8800 horizontal mill. The spindle spins fast, small chips and dust spray out of the hole, and the cut keeps eating metal at 700 SFM with a .250 feed. That is a lot of cutter at work in one spot.



The holding method stands out to me. The block is clamped from the top with plates fastened down by long threaded bolts. For cuts this aggressive, that looks like a sensible way to keep a large part from going anywhere, at least in my view.



The detail I keep coming back to is the spindle carrying an extended tool that reaches down into the internal pocket. Running a cutter that size on an extension is where I would expect any chatter or deflection to show up first, and nothing in the run suggests trouble there.



One open item is insert management. Edges get turned to a fresh position about every three hours, which is a hands-on maintenance rhythm to keep up with. There are also no material removal rate figures shared yet, which is the number many people would want before comparing notes. Coolant droplets on the enclosure walls and the machine base give a sense of how wet this cut runs.


Curious about the inserts here. How long does an edge stay in the cut before the maker indexes it, and is that timing done by the clock or by eyeballing the wear? With a cutter that diameter feeding that hard, I would guess the wear lands show up quickly.

The extended tool reaching into the pocket is the choice I would flag. My take is that it is clever to keep the 3-inch cutter working down in the cavity rather than stopping short, but the longer the overhang, the less I would trust the finish at the bottom. Reach versus rigidity, as I see it.

A concrete suggestion: work out and share the material removal rate for this cut. With a 3-inch cutter running 700 SFM and a .250 feed, the math should be straightforward, and hard numbers would let everyone judge whether these parameters sit comfortably or right at the limit for A106.

The maker has said insert edges get rotated to a fresh position after roughly three hours of use. Nothing has been said about whether that interval is kept by the clock or decided by inspecting the wear, so on that point the maker has not said.

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