Objective

Ascertain the feasibility of machining the fin edges from Ti Al6V4 to realize mass savings and performance improvements

Bandsaw

5 minutes on the bandsaw failed to move any material. The bandsaw is not a feasible way of cutting titanium, at least not one with cheap blades, no coolant, etc.

Mill

I tried a 1/8 in end mill at 180 SFM, .0010 chipload per tooth. This resulted in a spindle speed of 5000 RPM and a feed rate of 10 IPM. The endmill broke after 4 inches of cutting.

I tried a 1/8 in ball end mill at 180 SFM .0010 chipload per tooth. I used a spindle speed of 5000 RPM and a feed rate of 6 IPM. This was very successful for the slot cuts, but failed to be effective in plunging cuts.

Cooling is very important. I turned the mist coolant up to 10, use air-blast to help evacuate chips, and brushed on extra lubricant for good measure.