When to Use Shoulder Milling Inserts？

I have been making these blocks 3 x5 2.5 thick for a customer for a couple of years now and now we're doing 200-300 per month. Running them on a Hurco VM-10 15 HP spindle. We have been cutting the top with a 1/2" aluminum specific stub .75" LOC with HSM 30% engagement 125IPM 8K RPM =100% spindle load.

Just wondering if this might be a good candidate for 2" shoulder mil? We also have a 1" 2 flute ripper mill but that thing makes so much noise when its cutting that nobody wants to use it

BTW, The boss is .5" tall.

It takes ~ 50 seconds to pocket the top which I don't think is too bad but since we're not doing a finish op the top op a little rough from tool deflection. Not sure the shoulder mill will be any faster but might leave a better finish.

Any thoughts or recommendations?

2-flute or 3-flute? Roughing and finishing with that end mill? Does the mill max out at 8k? Have you tried a 3/4" end mill? Do the bases of the bosses need to be square or is there a radius tolerance? I guess I'd try a bigger solid cutter and rough/finish all at once to start with. How long does the part take right now, and what are you trying to accomplish? Sorry I was adding some more info when you replied.

3 flute, It takes ~ 50 seconds to pocket the top which I don't think is too bad but since we're not doing a finish op the top op a little rough from tool deflection. Not sure the shoulder mill will be any faster but might leave a better finish.

Its a 10K spindle but 8K is the top of the torque curve.

There is no call out for a square corner so can probably get away with a .032R insert.

If it could save some time and a flatter floor then it may be worth having one around.

30% engagement, .150 wide... .5 deep, 125 ipm... That is less than 10 cubic inches per minute.

That should be less than a 3hp cut, and its pegging your 15hp spindle at 100%?????

Same thoughts..

Perhaps gutless at the top of the RPM range?

NM.. I should read, 10k max, 8k being max torque.. Still, seems like should be capable of more. I think you could push your endmill way harder. maybe you dont use a alum specifi endmill or this kind of endmill require more hp because we only have a 7.5hp toolroom mill and i did some pocketing the other day 0.472 deep 0.500 wide 75 ipm. At 100 IPM you could hear the drive working hard so we push the feed down a bit. We dont have any load meter but pocket took 10 min to do and was still going good. We use Niagara A345 endmill 1.250 loc with Ticn coating. Just a thought, but why not try some smaller-diameter aluminum-specific tools. The smaller diameter should reduce the torque required to move the tool through the cut.

I would try stepping down to a 3/8" or even 5/16" endmill, with no change in the cutting parameters, and see what your spindle-load does... (Including RPM, feed rate, D.O.C, and W.O.C.) If the spindle-load drops any at all, you may be able to squeeze more RPM and/or feed from the machine... OK had the wrong part in my mind

Lake shore 3 flute AL specific stub EM, 40% engagement 150IPM 8,000RPM 80% spindle load. I'm showing 14.25MMR. Tool shows 140HR in cut so who knows if the boy reset the counter the last time the tool was changed but still feels like a sharp edge.

Back to the question at hand, do you guys have a rule of thumb for deciding when to change to a shoulder mill?

Back to the question at hand, do you guys have a rule of thumb for deciding when to change to a shoulder mill?

Sounds like your tool life is already amazing, and reducing cycle time is your #1... So I'm going to focus on that.
I'm also reading "Shoulder Mill" = 90° insert mill that mounts like a face-mill

Look at SFM/RPM/machine power to find diameter of tool that will give optimal power @ optimal SFM:
Sounds like you already know your max power is at 8,000RPM.
0.5" Tool @ RPM = SFM.... Slow for most aluminum inserts
3/4" Tool @ RPM = SFM... Could be good depending on carbide grade.
1" Tool @ RPM = SFM.... Now we're talking
2" Tool @ RPM = SFM... Likely too fast = reduced tool life.
.... Then again your using HSM techniques so best results come from higher than normal SFM.

Since you need the 90° tool for the part features, I think getting the shortest tool/holder length will make the biggest difference to surface flatness since it makes a very big difference to stiffness/bending torque.

Lake shore 3 flute AL specific stub EM, 40% engagement 150IPM 8,000RPM 80% spindle load. I'm showing 14.25MMR.

I'm not sure what this should equate to in HP but Gwizard has a glitch and no matter what I put in the machines HP setup it defaults to 3 HP Sent Bob a note to see if he is aware of the problem. If anyone else is using Gwizard then you may want to take a look. Version 2.45

I'm not sure what this should equate to in HP but Gwizard has a glitch and no matter what I put in the machines HP setup it defaults to 3 HP Sent Bob a note to see if he is aware of the problem. If anyone else is using Gwizard then you may want to take a look. Version 2.45

Heh, substription model is evil.
AFAIK if you pay only for 3 years and your subscription runs out 3 HP is what you end up having.
So to remove the restriction you have to keep paying.

I'm not sure what this should equate to in HP but Gwizard has a glitch and no matter what I put in the machines HP setup it defaults to 3 HP Sent Bob a note to see if he is aware of the problem. If anyone else is using Gwizard then you may want to take a look. Version 2.45

Surely you have outgrown gwizard by now. It's OK for wannabes and hobbyists with nothing bigger than a Tormach.

If you’re looking to add more variety to your milling operations, or if you need to remove large amounts of material quickly, shoulder milling is the way to go. This type of milling is versatile and can be used on a variety of materials. In this guide, we’ll cover everything you need to know about shoulder milling, including the different types of tools you can use, how to choose them adequately for your application, and general tips on how to take your shoulder milling operations to the next level.

Goto Guangzhou Ruiyi Technology Co., Ltd. to know more.

Shoulder Milling

Shoulder milling is a machining process in which the cutter is positioned at an angle relative to the workpiece, rather than perpendicular to it. The purpose of a shoulder mill is to create flat, angular surfaces on the workpiece.

A more technical definition would state that shoulder milling is any operation in which the machine tool axis is tilted from the normal line of travel of the material being cut, in the general direction of the surface on which the cutter lies. A 90-degree shoulder is the most common angle, but other angles can be used depending on the application.

What makes a shoulder mill cutter ideal for milling flat, angular surfaces? The need for constant access to the workpiece surface and cutting tools may be its biggest benefit. In contrast to chucking, the milling process cuts from top to bottom and side to side rather than in a straight line.

The different Types of Shoulder Mill Cutters.

There are several types of milling cutters, each designed for a specific purpose. The most common are:

Square shoulder milling cutters

A traditional square shoulder milling cutter is used in the milling process to create a clean, sharp edge on the workpiece. The square shoulder cutter is first mounted on the spindle and the workpiece is secured in place. It is then moved across the surface of the workpiece, removing material as it goes.

End milling cutter

An end milling cutter is a type of milling cutter used in metalworking. It is similar to a drill bit in that it has a cutting edge at the end, but it is also like a router bit in that it has flutes or teeth on the sides.

End milling cutters have slots on both sides which can be used to direct the travel of the cutter along with the material. These slots can also be used to guide the cut being created by the cutter as it moves across the material.

The indexable shoulder milling cutter

Indexable cutters offer a great solution for machining large or small shoulders. The indexable inserts have multiple cutting edges, making them perfect for tackling any size shoulder. The cutter is secured by its flange which maintains a tight clamping action between the cutter and inserts. This system allows for the full use of the depth of cut produced by the cutter.

Are you interested in learning more about Shoulder Milling Inserts? Contact us today to secure an expert consultation!

Solid carbide cutters

Solid carbide milling cutters are used to produce precise, repeatable cuts in a variety of materials. The solid carbide body of the milling cutter reduces overall friction with the material being cut, which ensures the cutting edges stay sharp and produce clean cuts.

Face milling cutters

Face milling cutter tools typically have a larger cutter diameter than end milling tools and are used for machining flat surfaces, such as those found in shoulders. In some cases the profile of a part can be turned down to create a surface with less material, but which is still larger than a conventional end milling cutter.

How to select the right shoulder milling cutter for the job.

There are a few things you need to consider when selecting the right shoulder mill cutter for the right application.

The size of the workpiece.

The size of the workpiece will determine the size of the cutter. End milling cutters for example are the best option for working with small workpieces. They are specially designed for milling small workpieces and can be used on a wide variety of materials.

The material of the workpiece.

The material of the workpiece will determine the type of cutter you need. However, the best milling tool for a given material will also depend on a number of factors, including the specific application and the individual preferences of the user. However, some general tips on choosing the right milling tool for a given material include considering the hardness of the material, the type of finish desired, and the depth of the cut. Carbide-tipped shoulder mill cutters for example are good for milling most types of materials, including steel, cast iron, aluminum, and brass.

The speed of the spindle.

The speed of the spindle will determine the feed rate of the cutter. It is recommended to choose a cutter with a high-speed rating and a sharp cutting edge. Additionally, it is important to consider the material being cut and the depth of the cut when selecting a cutter.

The cutter head.

The cutter head will determine the ability of the cutter to cut in more than one direction. If you need to make beveled cuts or cuts at an angle, you will need a cutter head that will allow for those types of cuts. An ideal scutter would have a cutter head with a small diameter and a long cutting edge length. The cutter head should be able to rotate at high speeds and have a large number of cutting teeth.

Tips for successful shoulder milling operations.

Some recommendations for successful shoulder milling operation include:

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