Instructions on how to use milling cutters
1. Milling cutter clamping 2. Milling cutter vibration Due to the slight gap between the milling cutter and the tool holder, the tool may experience vibrations during the machining process.
1. Milling cutter clamping
2. Milling cutter vibration
Due to the tiny gap between the milling cutter and the tool holder, vibrations may occur during the machining process. These vibrations can cause uneven material removal along the cutting edge of the milling cutter’s circumference, leading to an increased chip load compared to the originally specified value—and ultimately compromising both machining accuracy and tool life. However, when the width of the machined groove happens to be slightly narrower than desired, intentional tool vibration can actually be used to enlarge the chip load, thereby achieving the required groove width. In such cases, though, the maximum amplitude of the cutter’s vibration should be kept below 0.02 mm; otherwise, stable cutting cannot be maintained. Under normal machining conditions, minimizing cutter vibration is always preferable.
When tool vibration occurs, consider reducing both the cutting speed and feed rate. If significant vibration persists even after both have been reduced by 40%, you should then evaluate decreasing the depth of cut.
If resonance occurs during machining, the causes may include excessive cutting speed, insufficient feed rate, inadequate tool rigidity, inadequate clamping force of the workpiece, or factors related to the workpiece shape or its clamping method. In such cases, measures should be taken, such as adjusting cutting parameters, enhancing tool rigidity, and increasing the feed rate.
End-milling cutting
In CNC milling operations performed on mold cavities or other workpiece features, when the cutting point is located in a concave area or deep cavity, it’s necessary to extend the overhang length of the milling cutter. However, if a long-flute milling cutter is used, its significant deflection can easily lead to vibrations, potentially causing tool breakage. Therefore, during machining, if only the cutting edges near the tool tip are actively engaged in the cut, it’s best to opt for a short-flute, long-shank milling cutter with an overall longer length.
When machining workpieces with large-diameter milling cutters on horizontal CNC machines, the deformation caused by the tool’s own weight tends to be more pronounced. In such cases, extra attention should be paid to addressing any issues arising from end-edge cutting performance. If a long-flute milling cutter must be employed, it’s crucial to drastically reduce both the cutting speed and feed rate to ensure stable and reliable operation.
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