This is not a completely fair comparison. We did not tap-test or try to optimize the indexable endmill as we did with the solid carbide, nor did we test it in multiple toolholders. This does illustrate how much of a difference can be made using a Machining Dynamics (tap-test or RCSA) Dashboard to instantly evaluate different machining strategies and utilize new milling tool paths. The metal removal rate of the indexable endmill was 5.4 cubic inches per minute while the smaller carbide endmill was over 5X greater at 36.7. Even with a higher per tool cost (endmill vs. double sided insert), with a good resharpening program, the true cost was significantly less. More about resharpening and dynamics in an earlier post:
Of course, the indexable may very well perform better in other applications when fully optimized.
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