RoughingEnd Mill

You could try doing the bulk of the cutting with the McFly and then switch to the 1/4" using Rest Machining and 1.0" as your previous tool. The more aggressive cutting with the 1/4" as suggested may be quicker, but depending on your material being cut, you could probably push the McFly a little harder as well.

Sometimes, it’s all about the finishing touch. Grinding is like the artist’s brushstroke that smoothens the rough edges and elevates the appearance of your steel parts. The steel’s surface is carefully refined using a grinding wheel, eliminating imperfections.

There are a few version of these. They are much more common in larger cutters. You’ll find them listed under “roughing”, “corncob”, and “chipbreaker”. Be careful with those last 2 though as they are also common terms for types of composite and metal cutters that are not intended for things as soft as wood. A quick rule of thumb would be that if it’s more than 3 flutes with those terms it’s probably meant for metal or composites. 2 and 3 flute ones you’ll need to check.

I bought a bowl and tray bit with the intention of doing something similar. I haven’t used it yet and read concerns online about their ability to really evacuate the chips as well.

Tips and Considerations: To master surface finishes, it’s essential to match the finish to the purpose. Each finish has a unique benefit – powder coating for corrosion resistance, carburizing for wear resistance, nickel plating for added durability, and grinding for a polished appearance.

I saw this from IDC The “HOG” 1/4" Roughing Endmill Bit For CNC Routers, 1/4" Shank – IDC Woodcraft I googled for something similar and did not find a good selection, it mostly came back with metal milling machines roughing bits. One person said they are made form metal but work really well with wood.

Difference betweenroughingand finishing operations in machining

Machining steel demands precision and the right parameters. Whether delving into steel machining services, precision steel machining, or steel CNC milling, nailing down these three critical factors is your key to success.

I saw this from IDC The "HOG" 1/4" Roughing Endmill Bit For CNC Routers, 1/4" Shank – IDC Woodcraft I googled for something similar and did not find a good selection, it mostly came back with metal milling machines roughing bits. One person said they are made form metal but work really well with wood.

Eventually, you get a sleek, polished finish that looks great and ensures the steel meets your specifications. Whether it’s about aesthetics or precision, grinding is the final flourish that takes parts manufactured through steel prototyping to the next level.

Once you’ve manufactured the steel machined part, it’s time to get that perfect finishing to make the product ready to use. Below are a few surface finishing methods commonly considered for precision steel machining:

This grade, rich in alloying elements like chromium and molybdenum, offers excellent toughness, machinability, and stress resistance. It’s used in construction and aircraft engine mountings. Despite being heat-treatable, welding can be challenging.

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With our expertise and dedication to quality, we’re here to offer top-notch steel machining services every step of the way. Your steel projects deserve the best, and that’s what we’re here to deliver.

The choice of tool depends on your steel type and project requirements. Stainless steel, with its alloying elements like chromium, can be challenging to machine. Opt for tools and inserts explicitly designed to enhance tool life and chip load for stainless steel.

Known as mild carbon steel, 1018 steel is prized for its weldability, making it a top choice for carburized CNC steel parts. However, it might not be compatible with all finishing processes and comes at a relatively higher cost.

Featuring high sulfur content, 1215 steel is free machining and often used in automatic screw machine processes. It forms small chips during machining, allowing for higher machining rates. It’s suitable for heavy machining projects, such as studs, pins, screws, couplings, and hose fittings.

A medium carbon steel, 1045 is strong, tough, and water-resistant. It’s used in various CNC steel machining projects, including axles, bolts, gears, shafts, and studs. While machinable and weldable, it’s not recommended for extremely robust products.

This layer isn’t just for show; it’s engineered to withstand corrosion like a champ. The thickness typically ranges from 0.15 to 0.3 mm, ensuring your steel machine parts remain corrosion-free and resilient for the long haul.

The magic happens when this layer enhances the steel’s resistance to corrosion and wear. It’s like giving your parts manufactured through steel prototyping a polished, protective shield. Whether your steel components face the elements or heavy-duty wear and tear, nickel plating has covered them.

I used it recently clearing a large area for a serving tray/cutting board and it saved time over the 1/4" (default settings), but the depth was only 0.09".

Usually folks just use a #201 for clearing large pockets, then use a bowl-bit to finish up the bottom and sides and lower corners/edges.

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While steel machining is a crucial manufacturing process, mastering it requires attention to detail and the right techniques. Precision is key, from selecting the right steel grade to optimizing machining parameters and minimizing vibrations.

I am asking the group on how you would attack removing all this material. IE: Push the speeds, feeds, and stepover and what bit would you use?

Hand tools are a reliable choice for steel machining, offering decent accuracy and finish. However, they operate slower, making them ideal for small-scale projects with budget constraints.

I believe I have some things to try and see how much I can push a #201 bit and maybe order a cheap rougher just to see how it works

These are ideal for machining PVC, Acrylic & Hard Woods Solid Carbide 2 Flute Up Cut Router Bits Speeds, Feeds & Chip Load Chart Dimensions - Cutting Diameter Flute Length Overall Length Shank Diameter 1/16" 6mm 38mm 3.175mm (1/8") 1/16" 8mm...

Steel is ductile and can produce long, clingy chips threatening your cutting tool. Here’s why a 2- or 3-flute end mill is your best bet:

When you need your steel machined parts to be tough as nails, carburizing is the secret weapon. This process involves heating the steel with carbon-rich materials, like carbon monoxide or charcoal.

Roughingagriculture

Steel is a common metal that is important in many businesses worldwide. Its versatility and strength make it a top choice for manufacturers aiming to meet precise product specifications. Among the various metal machining services, steel CNC machining is a highly automated and versatile process. Yet, achieving optimal results in machining steel requires a nuanced approach. In this article, we delve into the intricacies of CNC steel machining, providing essential insights to help you attain the best outcomes.

That is interesting but makes sense. I thought they might be to big but then I use them all the time in my hand held routers. I have to think more on this as my bits I have to ramp in. there is no cutter in the middle of the bit. and then there is the chip removal. maybe a bowl bit, I will have to look in my collection Well I guess I will have to try some things Thanks, you got me thinking

Selecting the right material is paramount in CNC steel machining, and steel offers a world of possibilities. But how do you pick the right steel grade for your project? Let’s explore some common steel grades and their properties to help you make informed decisions.

For thin steel workpieces demanding utmost precision, water jet and laser cutters excel. They offer unparalleled accuracy and produce high-quality finishes. However, they are comparatively costly and better suited for specialized tasks.

Face milling

In general these run on the idea of breaking the flute engagement during the cut reducing total bit deflection (less time being pulled into the cut per flute). You can kind of think of it as each section of the flute being it’s own small cutter. That usually comes at the cost of cut quality and can cause weird effects with variable chipload. The exception to this was that chipbreakers were originally intended for a similar purpose but with the breaks in the flute being overlapped by another flute to give a smooth edge. However, it will depend on the manufacturer if that is true for any given bit. They were also usually designed for deeper cutting than you may be able to achieve.

So I thought maybe I will hog it out with something different and then use the bowl and tray bit for the final cleanup and to get the appropriate radius on the bottom.

For those times when you want both style and substance, nickel plating steps in. This surface finish takes your CNC steel parts to the next level. A thin layer of nickel, approximately 0.1 mm thick, is electroplated onto the steel’s surface.

@TDA thanks, Yes they seem to be more for bigger machines and yes I believe the idea is to break the chips up so we can get them out of the way faster. yes it leave a very rough cut but that the job of the finishing bit to fix

Rough CNC meaning

CNC mills shine in steel machining when precision cuts and excellent surface finish are paramount. They balance accuracy and speed, making them a versatile choice for various steel applications.

I have found I can push an 8mm quite a bit harder through ply and hardwoods than a 1/4" before getting the “I’m going to snap” noise

What does it do? It transforms the surface of your CNC steel parts into an impenetrable fortress. The result? Exceptional hardness and resistance to wear. Carburizing doesn’t just make your parts durable; it ensures they can take a beating and keep on going.

Rough finish meaning

Mortising bits have cutters on the outer edges and nothing in the middle so you don’t really need to worry about ramping them in.

Powder coating is a game-changer for your steel CNC milling. It’s like giving your components a suit of armor. A dry powder is expertly applied to the steel surface in this process, forming a robust layer.

With low alloy composition, including chromium, molybdenum, and manganese, 4140 steel boasts enhanced strength, flexibility, and corrosion resistance. It’s ideal for couplings, spindles, bolts, nuts, and automotive steel machined parts. However, welding may require pre- and post-heat treatment.

First step would be to push your DOC - CC is very conservative, you can very likely go to .100 or even .125 (1/2 the width of the bit). Feedrate can likely be higher as well, in the 100IPM range. Try both on a piece of scrap.

Moreover, you can consider using carbide and high-speed steel tools for their robustness and abrasion resistance, enabling faster cutting and longer tool life. Lastly, tools coated with Calico Aluminium Titanium Nitride (AlTiN) are preferred for roughing and semi-finishing. At the same time, Titanium Aluminium Nitride (TiAlN) coatings excel in dry high-speed finishing and general machining.

Hey all, I have a bunch of large catchalls trays to carve. 16 x 20 x 2 inches. It requires a lot of wood to be hogged out. CC says it will take over 6 hours to just rough out the trays with a 1/4 flat endmill with default settings.

I run 3/4 to 1" mortising bits with 1/4 shank. Operated about 13000rpm and feed rates between 700 and 1000 (in mm of course). Plunge rate of 200 to 250. Stepovers are 40% of the bit. I shave off over 75% of the time on average. I suggest a mortising bit because they allow for great chip extraction and also allow the bit to plunge without jamming up the machine.

Rough machining process

I Googled my way into confusion and doubt So I thought I would ask the experts here How would you quickly rough hog all this out ?

Don’t forget the importance of post-processing for that flawless finish. In your journey to achieve top-notch steel machining results, remember that Prototool is a trusted partner in the manufacturing industry.

I have a 2.2kW spindle however and am lucky enough to be able to run 1/2" cutters, for lots of wood removal I can’t do with the table saw or thicknesser, I use one of these as a cheap cutter for bulk removal

Usual preface, I’m with PreciseBits so while I try to only post general information take everything I say with the understanding that I have a bias.

Machining steel generates heat, which can wreak havoc on your tools and workpieces. Here’s how cutting fluid comes to the rescue:

Regarding steel machining, the right tools and techniques can make all the difference. Whether you’re exploring the process of steel CNC milling or tackling steel manufacturing, understanding the tools at your disposal is crucial. Here’s your comprehensive guide:

Remember that precision steel machining often involves specific surface finishes tailored to the part’s function and design. And lastly, achieving the perfect surface finish requires expertise.

Go buy yourself the cheapest mortising bit you can find. I get them from a local place here in town for $4.99. They are inexpensive and last a long time. Just slow down the plunge rate if you like. Mortising bits have cutters on the outer edges and nothing in the middle so you don’t really need to worry about ramping them in. You can also get a cheap bottom finishing bit and use the to hog out material if you can’t control your plunge rate. Remember that these larger sized bits run better at lower RPM. I run the 1/4 inch bits between 18 and 19000 but these larger bits I run around 13000 to 15000.

I don’t think the cutting geometry of the McFly is suited to large-scale material removal — it doesn’t have much in the way of flutes to clear chips — the design seems optimized for surfacing.