03-18-2016, 08:50 AM
TomG,
I saw cut the waste material at the lowest speed on the HF band saw and used a lot of WD-40 to keep it lubricated. It cut easily and when I cut the last bit by hand using the saw vertically very little pressure was needed.
My end mill could be dull because the carbide insert end mill left a much better finish. I always use some dark cutting oil with the end mills. It smokes a little but I don't mind the smell and I have a small fan set up to blow it away. I'll do some experiments with the scrap block I cut out with the saw.
My plan for the slot is to pre-drill holes with 1/8" drill bit and then use a long 5/32" end mill to remove the rest of the material. I am also looking at making a 0.165" broach from a square 3/16" tool bit and using the mill to nibble out the remaining material in the corners at the back of the slot where the end mill will leave a radius. I'll probably just file out the corners because there will be very little material and I've never made a broach before. But, like all things there is always a first time.
JScott
I saw cut the waste material at the lowest speed on the HF band saw and used a lot of WD-40 to keep it lubricated. It cut easily and when I cut the last bit by hand using the saw vertically very little pressure was needed.
My end mill could be dull because the carbide insert end mill left a much better finish. I always use some dark cutting oil with the end mills. It smokes a little but I don't mind the smell and I have a small fan set up to blow it away. I'll do some experiments with the scrap block I cut out with the saw.
My plan for the slot is to pre-drill holes with 1/8" drill bit and then use a long 5/32" end mill to remove the rest of the material. I am also looking at making a 0.165" broach from a square 3/16" tool bit and using the mill to nibble out the remaining material in the corners at the back of the slot where the end mill will leave a radius. I'll probably just file out the corners because there will be very little material and I've never made a broach before. But, like all things there is always a first time.
JScott
JScott, proud to be a member of MetalworkingFun Forum since Mar 2014.