Here's a scenario:
You're using a 1.5” 2 flute indexable endmill, cutting .100 deep per pass (radial and axial). You want to mill a very long slot (56”) in A36 material in a very old mill that has a morse taper spindle. There have been some modifications to the machine spindle so now the tool hangs out 22”. This causes excessive chatter. Your set-up for the workpieces is 2 long plates approx. 4.5” apart from each other at 56” long and the “slot” needs to be opened up to 5” at .875 deep.
Now you've decided to look for a better tool to help get rid of the chatter.
Here's what we recommend: stay with that tool to rough the slot, leaving approx. .030 of stock for finishing. Then use a solid carbide endmill 1” diameter and 1” length of cut 5 flute with a variable index and an AlTiN coating to run dry along with a brand new endmill holder with a 6MT shank for his machine. You should be “climb cutting” to help cut down on the chatter and this should help reduce the chatter overall but with a tool sticking out of the spindle 22” there is not a tool that can eliminate that chatter altogether.
What do you think? Have any similar experiences?