11-05-2012, 07:36 AM
That's a great question, Darren.
Generally speaking, it takes X amount of horsepower to remove X volume of metal in X amount of time. There are a great many variables at work, so how much you can actually cut varies widely. A cutting tool is a cutting tool, and the only difference between HSS and carbide these days is the speed you use in a given material. Other factors affecting milling cuts are:
Width of cut vs. cutter width
Shear angle of the cutter edge
Lead angle of the cutter edge
Sharpness of the cutter edge
Top form geometry of an insert or hook in the HSS cutter's edge
The key to getting the highest material removal rate is chip-thinning. Those 4" and 2-1/2" cutters with the 45º lead angle and about 15º shear angle reduce force so much that I'm able to get a surprising width or depth of cut with only 1HP at hand. A straight-flute shoulder mill of the same same would stall the motor instantly.
I goota get going, I'll post more later if you guys want more info and perhaps videos.
Generally speaking, it takes X amount of horsepower to remove X volume of metal in X amount of time. There are a great many variables at work, so how much you can actually cut varies widely. A cutting tool is a cutting tool, and the only difference between HSS and carbide these days is the speed you use in a given material. Other factors affecting milling cuts are:
Width of cut vs. cutter width
Shear angle of the cutter edge
Lead angle of the cutter edge
Sharpness of the cutter edge
Top form geometry of an insert or hook in the HSS cutter's edge
The key to getting the highest material removal rate is chip-thinning. Those 4" and 2-1/2" cutters with the 45º lead angle and about 15º shear angle reduce force so much that I'm able to get a surprising width or depth of cut with only 1HP at hand. A straight-flute shoulder mill of the same same would stall the motor instantly.
I goota get going, I'll post more later if you guys want more info and perhaps videos.