machining a internal recess

[Mickyd1]

Hello

I've got to machine a box type component about 300 x 200 x 150 size with a wall thickness of 4mm. On one wall there is a recess on the inside of 1mm. I wasn't sure what type of cutter to use was thinking of a woodruff type but not sure about the finish it would leave.

Any ideas of the best way?

Thanks in advance Mick

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[SteveLucas]

Mick,

There are not a lot of choices for undercutting tools other than woddruff key cutters and a few lollipop style.

I generally use a woodruff cutter. Just remember where the tool tip Csys is off from. Top Bottom or Middle of the cutter. you have to offset the cut for the thickness according to the tool tip Csys.

Steve

[Mickyd1]

Thanks Steve will remember that when I do the job. I was debating whether to get an end mill relieved so will have longer flute and better finish?

[TomD.inPDX]

they do make right angle mill heads... just sayin'

[SteveLucas]

20 to 300 Dollar cost of a cutter versus the cost of a right angle head.... I'll take the cutter.

I do have a nice PH Horn mill grooving tool that is inserted. You can get different cutter thickness with that but the diameter is limited. I use that for undercutting and things like snap ring grooves in bores.

[TomD.inPDX]

I guess that depends on the shape of the feature and how well equipped the shop is. If leading and training radii in the feature are permissible, of course a z-axis cut is perfectly acceptable. I've had clients that want pocket mills on the inside sides of a box along wth a 16 [0.4] finish. And the customer is always right, right?

[Mickyd1]

Thanks for advice guys the recess is 3mm deep and 200 x 100mm it has 20mm rads at the ends but sharp top and bottom,still thinking of a 25mm sdrill with a reduced shank.

[TomD.inPDX]

If there is no lip, then 3mm is easy. That's a pretty long shank though

What's the material? What's the finish requirement?

[Mickyd1]

Its only ally 6082 and I don't think there's a surface finish tolerance as its on the inside. The only lip is at the top and bottom. I'm hoping the cutter being carbide will b nice and sturdy,fingers crossed.

[JasonPensack]

We use AB Tool Woodruff Cutters all of the time for undercuts. They give a great finish (no problem holding 32 Ra all day in aluminum). They also have great pricing on customs which is what we use all of the time. Just fill out a form and you'll see it in 3-5 days.

[SteveLucas]

Jason,

the AB Tool shear hog mills kick butt in Aluminum. I had a couple of them in the last place I worked. you could really get some fast speeds and feeds with them as well as nice finishes. Unfortunately the only thing I get to cut any more is steel and a lot of that is hardened to 54-56 Rc.

Never tried the woodruff cutters though I have been getting mine from Harvey Tool. Mainly smaller diameter stuff.

Steve

[JasonPensack]

Steve,

I see them all of the time in the book. I will have to try and get one in here on a test. As for Harvey I use them a lot as well for standard sizes. I also love their stub flute long reach endmills since I do so many deep parts with down to .045" diameter endmills.

[Mickyd1]

Do they have a base in the UK?

[SteveLucas]

Looks like AB Tools is just in the US. I looked in the distributor list and didn't see anything overseas Michael.

[joshuataylor]

Thumbs up for ABtool woodruff cutters and shearhogs

Josh