11-19-2012, 05:08 AM
Hello to all 
Sorry for the late reply to Ed's question. My computer was two weeks out of service.
If I have very heavily rusted steel I remove it with an old screwdriver or an old chisel. Then I mill with a roughing end mill cutter down to the naked steel. Then I use a surface milling tool with hard metal inserts for a flat plane surface. For the final touch, I use new or little-used new inserts and milling than with 1600 revs / min a layer of only a few hundredths of a mm. You will see that you get a beautiful flat and shiny surface.
For round steel I use the same procedure on my lathe.
It is important that your mills or cut the first pass through the rust down to the naked steel. The cutting tool gets otherwise too many strokes and will be immediately blunt.
Good luck
Gerard
Sorry for the late reply to Ed's question. My computer was two weeks out of service.
If I have very heavily rusted steel I remove it with an old screwdriver or an old chisel. Then I mill with a roughing end mill cutter down to the naked steel. Then I use a surface milling tool with hard metal inserts for a flat plane surface. For the final touch, I use new or little-used new inserts and milling than with 1600 revs / min a layer of only a few hundredths of a mm. You will see that you get a beautiful flat and shiny surface.
For round steel I use the same procedure on my lathe.
It is important that your mills or cut the first pass through the rust down to the naked steel. The cutting tool gets otherwise too many strokes and will be immediately blunt.
Good luck
Gerard