Global Catalog Metric 8-16-23 web - Flipbook - Page 24
• •Whenever
Whenever
• Whenever
possible,
possible,
possible,
select
select
select
an
anend
end
anmill
end
millwith
with
mill the
with
thelargest
largest
the largest
diameter,
diameter,
diameter,
shortest
shortest
shortest
flute
flutelength,
flute
length,
length,
and
andshortest
and
shortest
shortest
overall
overall
overall
length
length
length
for
forthe
the
forbest
best
the rigidity
best
rigidity
rigidity
Application
Tips
• •Long
Long
• Long
flute
flutetools
flute
toolstools
are
arenot
not
areintended
intended
not intended
for
forpocketing,
pocketing,
for pocketing,
slotting,
slotting,
slotting,
ororheavy
heavy
or heavy
profiling
profiling
profiling
––limit
limit
–Rw
limit
Rwtoto
Rw
.02D
.02D
to .02D
Tool
• •High
High
• High
Performance
Performance
Performance
tools
toolstools
minimize
minimize
minimize
cycle
cycle
cycle
time
timeand
time
andextend
and
extend
extend
tool
toollife
tool
life life
• Whenever possible, select an end mill with the largest diameter, shortest flute length, and shortest overall
length for the best rigidity
• •Holders
Holders
•
Holders
with
with
adequate
with
adequate
adequate
gripping
gripping
pressure
pressure
pressure
andTIR
and
TIRare
are
TIRrequired
required
are required
• Long
flute
tools
are
notgripping
intended
forand
pocketing,
slotting,
or heavy profiling – limit Ae to .02D
• •Stub
Stub
Stub
holders
holders
holders
ororzero
zero
or length
zero
length
length
collet
collet
collet
style
stylestyle
holders
holders
holders
are
arerecommended
recommended
are extend
recommended
for
heavy
heavy
for heavy
stock
stock
stock
removal
removal
removal
•• High
Performance
tools
minimise
cycle
time
and
toolfor
life
• •When
When
• When
using
using
using
solid
solidsolid
holders,
holders,
holders,
hand
handhand
ground
ground
ground
screw
screw
screw
flats
flatsare
flats
arenot
not
arerecommended
recommended
not recommended
• Holders with adequate gripping pressure and TIR are required
Tool Holders
• •Secure
Secure
Secure
clamping
clamping
clamping
ofor
ofthe
the
ofworkpiece
workpiece
the
workpiece
will
willreduce
reduce
will reduce
chatter
chatter
chatter
and
and
deflection
and
deflection
deflectionfor heavy stock removal
•• Stub
holders
zero
length
collet
style
holders
are
recommended
• When using solid holders, hand ground screw flats are not recommended
Workpiece
• •Spindle
Spindle
• Spindle
must
mustmust
be
beininbe
optimum
optimum
in optimum
condition
condition
condition
for
forprecise
precise
for precise
TIR
TIRand
and
TIRmaximum
and
maximum
maximum
tool
toollife
tool
life life
•
Secure
clamping
of
the
workpiece
will
reduce
chatter
and
deflection
• •Sufficient
Sufficient
• Sufficient
horsepower
horsepower
horsepower
isisrequired
required
is required
totoperform
perform
to perform
atatrecommended
recommended
at recommended
speeds
speeds
speeds
and
andfeeds
and
feeds
feeds
Machine
• •Reduce
Reduce
• Reduce
rates
ratesrates
for
forlow
low
forpower
low
power
power
machines
machines
machines
totoprevent
prevent
to prevent
workpiece
workpiece
workpiece
and
and/ and
/orortool
tool
/ ordamage
tool
damage
damage
• Spindle must be in optimum condition for precise TIR and maximum tool life
•• Sufficient
horsepower
is use
required
to
perform
atliquid
recommended
and feeds
• •Avoid
Avoid
Avoid
re-milling
re-milling
re-milling
chips
chips
chips
through
through
through
useofuse
ofair
airof
blast
blast
air
blast
ororliquid
liquid
or
coolant
coolant
coolant
as
asnecessary
necessary
asspeeds
necessary
•
Reduce
rates
for
low
power
machines
to
prevent
workpiece
and
/
or
tool
damage
• •Maintain
Maintain
• Maintain
clean
clean
clean
coolant
coolant
coolant
with
withappropriate
with
appropriate
appropriate
concentration
concentration
concentration
Coolant
Methods
• •General
General
• General
recommendations:
recommendations:
recommendations:
• Avoid re-milling chips through use of air blast or liquid coolant as necessary
–Water
–Water
–Water
Soluble
Soluble
Soluble
Oil
OilororOil
Air
Air
orBlast:
Blast:
Air Blast:
Tool
ToolSteels,
Tool
Steels,
Steels,
Mold
MoldMold
&&Die
Die
&Steels,
Steels,
Die Steels,
Carbon
Carbon
Carbon
ororAlloy
Alloy
or Alloy
Steels
Steels
Steels
• Maintain clean coolant with appropriate concentration
–Water
–Water
–Water
Soluble
Soluble
Soluble
Oil:
Oil:Stainless
Stainless
Oil: Stainless
Steels,
Steels,
Steels,
Titanium,
Titanium,
Titanium,
High
HighHigh
Temperature
Temperature
Temperature
Alloys,
Alloys,
Alloys,
Non-Ferrous
Non-Ferrous
Non-Ferrous
Alloys
Alloys
Alloys
• General recommendations:
—Water Soluble Oil or Air Blast: Tool Steels, Mold & Die Steels, Carbon or Alloy Steels
• •Climb
Climb
• Climb
milling
milling
milling
isisgenerally
generally
is generally
preferred
preferred
preferred
—Water Soluble Oil: Stainless Steels, Titanium, High Temperature Alloys, Non-Ferrous Alloys
• •Attention
Attention
• Attention
totoprogramming
programming
to programming
details,
details,
details,
tool
toolholders,
tool
holders,
holders,
TIR,
TIR,balance,
TIR,
balance,
balance,
fixturing,
fixturing,
fixturing,
etc.
etc.improve
etc.
improve
improve
cutting
cutting
cutting
tool
tool tool
performance
performance
performance
and
andextend
and
extend
extend
tool
toollife
tool
life life
• Climb milling is generally preferred
• Attention to programming details, tool holders, TIR, balance, fixturing, etc. improve cutting tool
performance and extend tool life
END MILLING GUIDELINE
Dcutting
DD1 1==cutting
diameter LL2 2==flute
Lflute
flute
length
diameter
diameter
length
1 = cutting
2 = length
DC = cutting diameter
APMX = flute length
Speeds
and
Feeds
for
Cut
are
on
Width
( ( Rw
and
Axial
Depth
) )
Speeds
and
for
are
on
Width
(Width
) )Ae
and
Depth
( Depth
Speeds
andFeeds
Feeds
forCut
Cut
Types
arebased
based
onRadial
Radial
Width
( Rw
Rw
and)Axial
Axial
Depth
(Ad
Ad)()Ad
Speeds
and
Feeds
forTypes
CutTypes
Types
arebased
based
onRadial
Radial
) and
Axial
( Ap
Reductions
to
and
may
be
when:
Rw
and
AdAp
exceed
recommendations
Reductions
totoSpeeds
and
may
necessary
when:
• •Rw
Ad
exceed
recommendations
Reductions
Speeds
andFeeds
Feeds
maybe
be
necessary
when:
Rw•and
and
Adand
exceed
recommendations
Reductions
to Speeds
Speeds
andFeeds
Feeds
may
benecessary
necessary
when:
• Ae
exceed
recommendations
• long
Using
long
flute
or extended
reach
• Using
long
flute
or extended
reach
toolstools
• •Using
flute
or
reach
tools
Using
long
flute
orextended
extended
reach
tools
• long
Using
long
tool
holders
• Using
long
tool
holders
• •Using
tool
holders
Using
long
tool
holders
• Machining
materials
harder
than
listed
• Machining
materials
harder
than
listed
• •Machining
materials
harder
than
Machining
materials
harder
thanlisted
listed
ENTRY METHODS
Helical
Helical
Helical
Ramp
Ramp
Ramp
Pre-Drilled
Pre-Drilled
Pre-Drilled
Hole
HoleHole
Pre-drilling is the preferred entry
Pre-drilling
ispreferred
the preferred
Pre-drilling
Pre-drilling
isisthe
the
preferred
method for most applications.
method
for most
entry
entryentry
method
method
for
formost
most
applications.
applications.
applications.
24
Plunge
Plunge
Plunge
Straight
Straight
Straight
Ramp
Ramp
Ramp
Alternative methods are helical and straight ramping. High
Alternative
methods
are helical
and
straight
ramping.
Alternative
methods
are
and
ramping.
Alternative
methods
arehelical
helical
andstraight
straight
ramping.
ramp angles require reduced feed. Lower ramp angles will
angles
require
reduced
Lower
High
ramp
angles
require
reduced
feed.
Lower
ramp
HighHigh
rampramp
angles
require
reduced
feed.feed.
Lower
rampramp
allow higher feed rates and extend tool life. Use slotting
angles
will
allow
higher
and
extend
tool
angles
will
higher
feed
rates
and
tool
angles
willallow
allow
higher
feedfeed
ratesrates
andextend
extend
toollife.
life. life.
speeds and feeds for ramp angles of 1° to 2°. Reduce feed to
Use
slotting
speeds
and
feeds
for ramp
angles
Use
speeds
and
for
angles
ofof1°1°of
toto1°
2°.
Useslotting
slotting
speeds
andfeeds
feeds
forramp
ramp
angles
2°.to 2°.
25% when ramp angles approach 6°. General purpose tools
Reduce
to when
25%
when
angles
approach
Reduce
feed
toto25%
ramp
angles
approach
6°.
Reduce
feedfeed
25%
when
rampramp
angles
approach
6°. 6°.
and/or difficult to machine materials will require lower ramp
General
purpose
and/or
difficult
to machine
General
purpose
tools
and/or
difficult
totomachine
General
purpose
toolstools
and/or
difficult
machine
angles and reduced feed.
materials
will
require
lower
angles
and
reduced
materials
will
lower
ramp
angles
and
feed.
materials
willrequire
require
lower
rampramp
angles
andreduced
reduced
feed.feed.
END MILLS
Plunge only in non-ferrous
Plunge
only
in non-ferrous
Plunge
only
Plunge
onlyin
innon-ferrous
non-ferrous
and short-chipping materials
and
short-chipping
materials
and
materials
andshort-chipping
short-chipping
materials
using slotting speeds and
using
slotting
speeds
using
slotting
speeds
and
using
slotting
speeds
and and
25% slotting feeds.
25%
slotting
feeds.
25%
feeds.
25%slotting
slotting
feeds.
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