Recently, one of our customers tried our Union Tool endmill in Titanium 6AL4v.
He was profiling with our 5 flute 6mm diameter endmill with an 18mm flute length. The radial engagement was .007" or .19mm. Axial engagement was .500" or 12.7mm. He was running our endmill @ 4500 RPM @ 110 IPM or 2794 mm per minute. He ran 40 parts and was extremely happy with the performance.
Recently we had an application drilling and counterboring 1018 steel for a customer where they had to drill 9 holes 3/8" x 2" deep. The machine was CAT 40 spindle with 300 PSI coolant thru the tool. The parts were fixtured in a vise- 5 parts to the vise. The customer was originally peck drilling and his cycle time for the 5 parts was > 1hour. Running our carbide drills (coolant fed) 3/8" diameter x 8Xdiameter, @ 5000 RPM @ .012" per rev, we drilled 45 holes in < 5 minutes. We then plunged a 1/2" diameter endmill 3/4" deep to create a counter bore @32" per minute. We ran into a problem with the chip control with the 1/2" endmill. So we then specified a 180 degree drill to drill the c'bore @ 2387 RPM @ .007" per rev. This took < 3 seconds per hole or 3 minutes for all 45 holes. The customer told me right there from his experience that we saved him 48 minutes in cycle time per 5 parts.
Plunge milling or Hi-Feed Milling? That is the question! LOL!! Actually it depends on the application. e.g. A while back, at a mold shop, the customer was looking at Hi-Feed milling some molds on a 5 axis vertical spindle CAT 40 machining center. The mold was of a good size and it had heavy scale on it as the material was 15-5 PH Stainless Condition 1025. the Hi-Feed cutter was 1" x 2 flute taking .050" DOC. The customer estimated that it would take 4 hours to mill around the periphery of the mold. We brought in a 3" x 6 tooth square shoulder face mill and by stepping over 30% of the mill by .100" radial depth of cut, we were able to reduce the cycle time from 4 hours to 1 hour. Also, the customer did not have to index the inserts for the job. But it all depends.