Can't find a slotting tool path that works, just breaking endmills.

[Anonymous]

Hello all, I'm attempting to make a replacement bracket out of 6061 aluminum that has a 0.148" wide slot. I am using a 0.125" cutter and am not having any success with my attempts. I have tried a slotting tool path with ramp and the tool and side walls are getting gummed up. The endmill breaks before it completes. My plan was to slot then rough out the corners then come in with a 2D countour for finishing passes. I didn't get past the slotting operation 😞

I have tried a 2D adaptive but it is only creating a tool path for the corner sections. I also tried a 2D contour but didn't like all the extra material it has to hog though in the corner area. Is there a better way I am missing here?

I have attached my drawing and what I am talking about is the big slot on the top side operation.

The Milling machine is a Makino KE-55 with spindle speed limited to 4000 RPM

Cutter is a new OSG 2 flute uncoated carbide in an ER32 holder

Thank you all!

[HughesTooling]

How about using multiple step downs and order by depth with the 2d contour and ramp so you clear the total width at each level. A bit time consuming but if it gets the job done that's all that matters?

See attached file.

Mark