I'm considering getting a face mill, and am looking for field reports
and suggestions. I've been using a fly cutter for facing, but it's slow
and probably hard on the bearings. This really is a job for a face mill.
I have a MVI vertical mill with the original low-speed 1 HP motor driven
from a VFD, with an R8 spindle.
My first question is how large a diameter is reasonable. I've heard
that such machines can spin a 3" face mill with no problem. Would that
that be for steel, or only for aluminum? What sizes have people used?
My second question is what make and model of face mill to get. Again,
what kinds have people used, and how well did the face mills work?
Thanks,
Joe Gwinn

You get what you pay for. One cadilac is the sandvik R390 3" face mill. Big
$ and worth every cent. These inserts run best without coolant - they put
the heat in the chip.
Karl

Volume of a solid bounded by a cylindrical surface is: V= ((4/3 x pi) x (radius
cubed)) = 14.1
cubic inches for a radius of 1.3inches.
According to Machinery's Handbook, and if all elements such as sharpness,
optimum rate of feed,
efficiency of power transmission, etc are taken into account:
The "K" factor (specific power consumption) of plain carbon steel is given as
0.63 HP required to
remove material at the rate of 1 cubic inch per minute. Therefore, it would
take 22.4 minutes to
remove 3 inches of material with 1 HP turning a 3" face mill. And that is if
everything else is
optimum. Thus it would take at least 22.4 minutes to remove the 14.1 cu.
inches. Not likely,
because of lost motion re. repeated passes.
A more reasonable diameter to cut on a 1 HP mill might be 1 inch. That works
out to 48 seconds; but
again would take longer because of lost motion between passes.
Bob Swinney
PS: Someone please check me on this because I'm pretty loopy right now because
of Vicodin taken for
a broken ankle, in a cast.
rbon Steel of Brinell 80-100 requires a unit HP of 0.63. Slinging a 3" face
mill of area Pi x R sq.
I'm considering getting a face mill, and am looking for field reports
and suggestions. I've been using a fly cutter for facing, but it's slow
and probably hard on the bearings. This really is a job for a face mill.
I have a MVI vertical mill with the original low-speed 1 HP motor driven
from a VFD, with an R8 spindle.
My first question is how large a diameter is reasonable. I've heard
that such machines can spin a 3" face mill with no problem. Would that
that be for steel, or only for aluminum? What sizes have people used?
My second question is what make and model of face mill to get. Again,
what kinds have people used, and how well did the face mills work?
Thanks,
Joe Gwinn

Make that radius 1.5 inches not 1.3 as my stupid PC thought I meant to type!
Volume of a solid bounded by a cylindrical surface is: V= ((4/3 x pi) x (radius
cubed)) = 14.1
cubic inches for a radius of 1.3inches.
According to Machinery's Handbook, and if all elements such as sharpness,
optimum rate of feed,
efficiency of power transmission, etc are taken into account:
The "K" factor (specific power consumption) of plain carbon steel is given as
0.63 HP required to
remove material at the rate of 1 cubic inch per minute. Therefore, it would
take 22.4 minutes to
remove 3 inches of material with 1 HP turning a 3" face mill. And that is if
everything else is
optimum. Thus it would take at least 22.4 minutes to remove the 14.1 cu.
inches. Not likely,
because of lost motion re. repeated passes.
A more reasonable diameter to cut on a 1 HP mill might be 1 inch. That works
out to 48 seconds; but
again would take longer because of lost motion between passes.
Bob Swinney
PS: Someone please check me on this because I'm pretty loopy right now because
of Vicodin taken for
a broken ankle, in a cast.
rbon Steel of Brinell 80-100 requires a unit HP of 0.63. Slinging a 3" face
mill of area Pi x R sq.
I'm considering getting a face mill, and am looking for field reports
and suggestions. I've been using a fly cutter for facing, but it's slow
and probably hard on the bearings. This really is a job for a face mill.
I have a MVI vertical mill with the original low-speed 1 HP motor driven
from a VFD, with an R8 spindle.
My first question is how large a diameter is reasonable. I've heard
that such machines can spin a 3" face mill with no problem. Would that
that be for steel, or only for aluminum? What sizes have people used?
My second question is what make and model of face mill to get. Again,
what kinds have people used, and how well did the face mills work?
Thanks,
Joe Gwinn

They look nice. Where are they sold?
What about the R245?
The Sandvik Coromont website seems too complicated for its own good, but
very good-looking.
Joe Gwinn

That would be for steel. The 3" may assume aluminum, which was one
question I had.
I'll have to run the numbers in the Machinery's Handbook calcs.
I cannot imagine cutting 14 cuin of metal using a flycutter.
Joe Gwinn

The only place you can afford it is on eBay. My son keeps joking about all
the people stealing these from work to auction on eBay.
I've not used this one.

That would be for steel. The 3" may assume aluminum, which was one
question I had.
I'll have to run the numbers in the Machinery's Handbook calcs.
I cannot imagine cutting 14 cuin of metal using a flycutter.
Joe Gwinn
The "K" factor, 0.63, was taken from Machinery's Handbook and it is for "plain
carbon steel" The
calculations were based on a radius of 1.5 inches.
Bob Swinney

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