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This is a common customer reaction when dealing with Inconel. It is a difficult material, but should it make shops run for the hills? Absolutely not! Common in the aerospace industry, Inconel is one of the toughest high temperature resistant materials. However, with the correct tool, it too can be easier to machine.

One of my customers working with Inconel was in need of a 5/8” end mill for a new project involving an aerospace engine part that they were quoting. After examining the job, we realized that removing all the material would be the biggest challenge.

For their slotting operation, I recommended OSG’s EXOCARB® Aero Rougher. Many people in the industry are familiar with older end mill designs such as the Corncob Rougher and Knuckle End Mill. Our Aero Rougher, however, is not just a typical Corncob Rougher. It is specially designed for maximum metal removal in exotic high temperature materials. The uniquely configured serrations on the cutting edge reduce friction, thereby generating less heat and requiring less horsepower than standard or variable helix carbide end mills. In addition, the combination of the shallow profile serration and the 45° helix provides a much smoother surface finish.

With it being a new project, my customer needed to make profit but also keep costs down in order to win the bid. To determine if the Aero Rougher was their best choice, we tested it against two other competitors that had a variable design.

To begin the test, we used the OSG recommended speeds and feeds for the application, 520 RPM at 2.7 IPM. With the majority of the cuts being a slot, we recommended 0.156” on the depth of cut (DOC).  In the end, the operator was delightfully surprised when he saw the results of the OSG tool performance. After several trials, the customer was able to push the Aero Rougher to 0.200” DOC. OSG scored lower in cost and provided the customer a completed part.  The competitors, on the other hand, were not even able to finish the job.

In today’s competitive market, OSG’s EXOCARB® Aero Rougher is able to provide users the ability to run tools with higher feed rates and deeper depths of cuts for reduced cutting time. It not only handles the tough and the nasty, but it helps eliminate stress when working with Inconel. 

The VGx series features chatter-free machining of a wide range of materials and milling applications. The VGx’s variable index and eccentric relief design helps eliminate chatter by breaking up harmonics that are produced during normal milling operations. For further stability and minimal wear, the VGx’s raised land configuration and OSG’s TiAIN coating keeps the VGx end mill cutting consistently at accelerated speeds.

With its sophisticated design, the VGx excels in difficult-to-machine materials, such as carbon, alloy steels, cast irons, stainless steels, titanium and nickel alloys, while maintaining high metal removal rates. This keeps inventory cost low due to the reduced need to stock multiple cutters.

We decided to run a test with the VGx versus the competitor’s end mill. The customer was cutting 410 Stainless Steel using a 1/4” and a 3/16” with .03 corner radius. We first ran the competitor’s end mill at 75 SFM, 4,800 RPM, and 38 IPM. To compare, we then ran the 3/16” VGx end mill at 290 SFM, 5,900 RPM, and 23 IPM. By using the VGx, we reduced the cycle time by two minutes on the 3/16” and by three minutes on the 1/4” cutter. Not only did we save the customer time, but the VGx produced twice as many parts for increased overall productivity.

After all the tests had been completed, the operator was still trying to wear out the OSG cutter with no success. The VGx End Mill far surpassed his expectation and was able to run with any materials that they cut, which finally sold the customer on the VGx series. They now stock over? 40 different styles of the HY-PRO® VGx End Mills and are ready to tackle any materials that come their way, proving that the “V” in VGx not only stands for “variable” – but “versatile” as well.

The OSG HY-PRO^® CARB VGx End Mill is a high performance variable geometry end mill, ideal for a variety of applications, including difficult-to-machine materials.

It features unequal flute spacing to reduce chatter and a raised land configuration, which provides increased stability when taking deeper depths of cut, thus enabling consistent performance and increased tool life.

The HY-PRO^® CARB VGx End Mill excels in all milling operations including slotting, side milling and pocketing, in both roughing and finishing applications.