Seeing that somebody was averse to the "too clean" look of our Mill, we did have a project to complete and took pics using our new KYOCERA MTP 90 CERATIP Facemill with the CERMET TN-60 Carbide Inserts, supposedly a HIGH-FEED HIGH CUTTING Tool - which we had seen in action on a popular channel, and which really created enough swarf to not only mess up our Machine but the whole area around it.
Our patient wait of some 6 weeks for the Tool to arrive was, to say the least, a bit disappointing. We had an proper opportunity to give this tool a run on a 24" piece of D2 which required just 1.5mm take-down.
On the first run the Tool seemed to have lost it depth of cut nearing the end of the workpiece, although we had torqued the Draw Bar adequately. We initially commenced cutting longitudinally, on the Auto Feed, but encountered too loud complaining from the Tool. Switching over to cutting in the Y direction manually seemed more pleasing to the Tool !!! However, this left those numerous ugly division cut-lines which we eventually removed switching to the X Auto Feed. (Hope we have our X's and Y's correct !!!)
During the cut the Inserts eventually worked themselves loose with 2 falling out completely !!! This was frightening. We have an Mitsibushi Octoturn 50 mm Facemill, or something called that, which feeds much slower, but which never behaved that way.
We were really anticipating this MTP Tool to plough through the D2 and get finished in no time. We did use it initially on another large Knife for Son, also on D2, with no drama. But working on this large piece seemed to have drained the Tool totally !!! After the inserts loosened and fell off we started afresh with 2 new Inserts, the one was still good, torqued them solid from the rear and found our bearings, somewhat.
We have attached progressive pics for verification commencing with the Full Length view, some of the Y cut, then the X run and the final finish cuts with cutting fluid only. (This should please the avid eye ballers)
Finally, and this leads us to finding out from U Folks if there is a better Tool out there or by the limitations of our knowledge and experience, we had executed something/s totally wrong here. "The fault dear Brutus lies not in our stars, but in ourselves" !!!
Would be nice to hear from U Guys.
Thanks in advance
Regards
aRM