Hi folks,
I have a part that needs a pocket/nest for a 1" diameter ball bearing to rest in. The diameter of the nest will be about 1.025 diameter and .5 deep. I want the part to be made out of aluminum and I need the finish to be smooth, with little visible tool marks. Am I better off to rough the nest out with a flat bottom endmill and finish with a ball end mill OR rough it out with a flat bottom endmill and finish it with a form cutter?
I worry the large bearing surface of a form cutter will create a lot of chatter, even with slow rpm and lots of coolant. I'm not sure if finishing the nest with a ball endmill, taking several passes, will leave a smooth enough finish.
Any help would be greatly appreciated.