The Science of Face Milling

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Like any concept in the world of machining, face milling can be done in a number of different ways. These are some of the basic concepts of how to do face milling and what tools you can utilize.

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The Science of Face Milling

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I still love the look of trochoidal marks no matter what people say

matthewlennox

Can you do one showing the math of all the Face mill cutting techniques? Or even the method of how to calculate the feed rate of a face mill and the how to find the chip load per tooth?

ninjaabcde

thank you very much for the knowledge sharing!

supunathukorala

Very nice video.

For low HP machines like the Tormach and typical entry level home shop and small shop machines, it's hard to beat the Tormach SuperFly for facing operations. Using only one insert ensures that there can be no insert misalignment so the surface finish is gorgeous, and if the tool is crashed, there is only one insert to replace (haven't crashed the SuperFly yet). I still need to get a second SuperFly, just because I'm so lazy that I don't want to change inserts when switching from aluminum to steel. Yeah, that's pretty lazy. The SuperFly is one tool that requires a good tramming of the spindle to avoid cutting a dished surface. It'll look smooth and it'll be smooth, but it won't be completely flat unless the mill is properly trammed.

LibertyEver

I don't get why some people say Tormach is underpowered or less rigid like it's the end of the world. It runs on a dryer circuit and does stuff WAY cooler than drying clothes. I mean, a DMG DMC1850V is probably gonna need 480 3-phase. Good luck hooking that up on a residential account.

A budget CNC coupled with a creative designer can really make effective use of the tool.

Dr_Xyzt

I'm doing a face milling job on 6" wide x 1" thick HR flat bar. Using a 2"shell style cutter, the issue I'm having is steps, .005-.006 deeper or shallower with every pass. I'm only taking a small bite, .010 -.015 dept. What could be my problem? Thanks

TedEntz-tqvx

Is it safe to use a large face mill on a small piece of stock without running the risk of it flying out of the vise? For example if you had a rectangular piece of aluminum stock that is 1/2 inch x 1/2 inch by 2 inch with the square side sitting on parallels and 0.02 inch clamped in the vise and you did a 0.50 inch face mill pass with a 3 inch face mill, could you expect that to cut just fine or would the stock likely just fly out of the vise?

bds