Extra long end mill

[kaizad]

I am looking for a HSS square end mill, 1 in. dia with 12" length of cut (minimum); number of flutes is not critical. I need it very quickly so if there is something off the shelf that would be ideal. Any suggestions?

 

[mcgyvr]

Good luck finding that.. Would a 2" diameter work? Typically 6" is the longest you will get in a 1" end mill.
I bet tool deflection is your worst enemy.

 

[ornerynorsk]

What is it you are trying to do with the cutter? Using one that you have described is totally impractical for use as an endmill, I suspect you've got some other use for it in mind. A good tool shop would be able to make whatever you need.

 

[williedawg]

Would be helpful to know what is being done.
Does the "cutter" need to cut the entire length?
If so, I agree with mcgyvr...tool deflection and chatter will be a bear.

If you're only concerned with making a cut at or near the bottom of a recess with minimal side contact; or a c'bore operation, then a standard end mill can be extended for that reach, however, you're still going to have chatter and tool deflection if the side cut is substantial.
We've silver-soldered such home-made tooling in the past to get down into a pocket.....some were nothing more than an endmill with a reduced shank joined to a solid shaft of good material such as 4140 or some other tool steel.
Have you looked at off-the-shelf counterbore tools that may be adapted to your needs?

 

[Astonlee]

9 times out of 10 its reach you need, rather than length of cut, as this length of cut it would have to be a special tool and it would suffer badly with deflection. I suggest you look at making your own shrink-fit extension with a 2xd flute length.

 

[mcgyvr]

I really think this is the 1 out of 10 as he is asking for a 12" length of cut.
I bet his machinist said.. "you designed it, you find the darn end mill"

 

[hbma]

I bet that too mcgyvr!

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