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I finally stopped roughing ALL my aluminum with a 3 flute and started using a 2 flute for the pockets
For 6 years I ran every 6061 job the same way, 3 flute carbide at 8000 rpm and .005 per tooth, and I thought chip evacuation was just something you lived with. Then a guy named Dale at the shop in Wichita showed me a 2 flute running 6500 rpm on a deep pocket job, and the chips came out like a fountain instead of getting recut. I tried it on a batch of 40 brackets and my cycle time went from 11 minutes to 8 and a half, with way less chatter in the corners. The tool life was the shocker, I got 3x the parts per end mill because the chips were not sitting in the cut getting rubbed around. My old 3 flute still wins on finish passes and thin walls, so it is not like I threw them all in the trash. What rpm and feed are you guys running on 2 flutes in deep pockets, because I am still dialing mine in?
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