View Single Post
Old Nov 21, 2012, 11:32 PM
Rich Speroni is offline
Find More Posts by Rich Speroni
Registered User
Rich Speroni's Avatar
United States, CA, Newman
Joined Jun 2003
416 Posts
I would use carbide stub, double ended .125 dia 4 flute endmill. Four flutes are stronger than 2 flutes. Length of cut for stubs is .25-.375 inch long. The shorter the better. Only let the endmill protrude from the collet the length of cut. So clamp it real close right up to the end of cut of the cutting tool.

To get the chips to clear the cutter you're going to need an air/water spray mist. The water cools the cutting tool and the air spray clears the chips. You need the air velocity to be high with a little water volume. The spray has to set very close to the .125 end mill directed towards the bottom of the cutter.

The best way to cut the those arms is first rough saw them out with a band saw. Leave no more than a 1/32 oversize (less is better). now all you have to do is use the side of the cutter to clean to size. You should be able to go the full 1/8 depth of cut. 10,000 RPM, 5-10 inches per min on feed. Much less stress on the cutter.

Before you do any saw cut put some holes down the length of the arms. Very little clearance for 1/4 in. screws. Space them out 1 inch from each end and every 3 inches down the arm . Now get a 4 inch wide x (2 inches longer than arms) piece of Alum plate or bar 1/2 inch thick, now put in 1/4-20 threaded holes that are the same spaced as the arms. Now clamp down the plate to the the table and the arms to the plate using 1/4-20 socket head screws and steel washers. You could use 1/8 Aluminum sheet strips for washers. Now you've got a rigid setup that won't move when you cut the arms. Use the water spray and clamping of the 4 flute cutter as described above to get it done.

Good Luck.
Rich Speroni is offline Find More Posts by Rich Speroni
Last edited by Rich Speroni; Nov 21, 2012 at 11:50 PM.
Reply With Quote