Need help milling Titanium with HSS endmills.

[Gwaed]

I have been asked to help save money on a titanium product we produce. I have read that you can use HSS cutters with success and possibly even cut cycle time versus using carbide. Currently we are using carbide cutters with tiain coatings. Any help is appreciated.

[Chuck]

First off, I would check out the December 2007 issue of American Machinist Magazine on page 52 and see if any of the info in that article helps. Then, I would contact some cutting tool manufacturers. I'm sure they would be more than willing to help you out, even if you don't purchase anything from them.
Here's a few that were part of the Dec article:
ATI Stellram, Iscar Metals, Kennametal, and Seco Tools.

[exkenna]

Gwaed,
Are you roughing out stock for a finish pass or just taking light cuts?
Also, what series Ti are you working with?
For example, 6AL4V is a much different situation than 10-2-3.

Are you pocketing or profiling?

The limiting factor for Ti is usually surface footage, 130 seems to be the max in most cases. 70-110 is typical for coated carbide. You're looking at 40-80 for HSS.

You may consider a coated M42 or powdered metal rougher and take a large bite.

Give us a few more details.

[Gwaed]

We are machining 6-4. Mainly profiling. We have been switching coolants trying to find an economical one. The pieces of Ti we get are drop pieces from another company and the hardness may differ? We currently are using a Iscar inserted cutter, but there are issues with the inserts not holding up. I am running the cutter at 800rpm and 7. in. min feed. Then finish with a 3/8 e-mill from dura-mill. The problem is with the roughing pass taking to long.

[big_mak]

I worked for an aerospace company that used HSS Cobalt endmills from Minicut International. 2
Diameter full width 1-1/4" Deep!!!!

Check them out.