millingprocess step-by step

I have not personally cut steel but I know you can as long as you are very careful and use a small tool. I would look at this for inspiration:

Before buying a new bit and wasting the cash can the shapeoko cut long passes of 1/4" thick mild steel using the default rates, lowest rpm setting on the dewalt trim router and w40 as coolant and some compressed air to clear the chips.

Steel MillingMachine

Milling steelpdf

I found that I kept chipping the corners off of endmills when trying to slot / contour cut in steel, especially when ramping (at higher DOC and feedrates, anyhow). Corner radius endmills solve that problem if you don’t mind machining .010/.015" into your wasteboard for full depth cuts. I like these ones from Lakeshore Carbide: CORNER RADIUS END MILLS

Endmilling steel

I usually use the shapeoko to mill hdpe, rubber, and a little bit of aluminum. I started experimenting with steel and I’m working on a 1/4" thick 4x6 part that has a couple of pockets and a contour cut. I started with a new bit but quickly burned it up (I had the RPMs set way too high) before I could finish contour cut. I tried my only other 1/4" end mill but I think it was too spent to use on steel.

Following these guidelines, I can easily get a full day out of a cutter, or if I use the higher number…about a half-day. It’s what I’ve use for 40+ years of machining and 5+ years on my Shapeoko.

In the interim I ran the operation really slow with a 0.005 doc. This really helped out but other than taking forever I was only able to cut 1 part before the bit got too dull. I think the dewalt router just runs too high of an rpm, even at the lowest setting.

Milling steelby hand

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I often cut steel on the Shapeoko and in fact, I spent most of the day today cutting some 1018 low carbon steel (Ref 1.25 dia). I was boring 5/8" holes in 1.0 inch long slugs and milling a 7/8 C’Bore 1/8" deep. Major cutting tool manufacturers will list the cutting rates for their tools for a general range of material. (HSS, Carbide and Coated Carbide, etc.)