Fault analysis countermeasures in end mill machining
#Fault analysis countermeasures in end mill machining

 

 


Selection of
tools material


Cutting conditions
Tools profile
Fixture of machine tools
select coated end mill

cutting speed

Feed

cutting depth
cutting direction
Cutting fluid
helical angle number of edge
mill diameter
shorten overhanging volume of tools
 
installation precision of tools
 
run-out precision of spindle and collet
 
maintenance and replacement of collet
 
Improve clamping retentivity 
improve installation rigidity of work piece
 
IncreaseJ

ReduceK


add more cutting fluid
non-water soluble cutting fluid
Dry.wet change
Increase J more

Decrease K less

Body damage

 

¢Damage of end mill

 

 
 

¢
K

¢
K
 
 
 
 
 

¢
K


J
¢


¢
 
 
¢
¢
 
Damage of
tools point
 

 

¢Quick wear of
cutting edge

 

¢

¢
K
J
¢

 
Climb milling
 
¢
 
 
J
¢

 
 
 
 
 
 
 

 

¢Damage (little chipping)

 

 

¢
K

¢
K

¢
K
Climb milling
 
 

¢
Dry
 
 
 
¢
 
¢
¢
 
¢

 

¢Chips on cutting edge

 

¢
 
 
 
 
¢


¢
Wet
J
¢

 
 
 
 
 
 
 
 
Machining precision
 
 
 
 
 

 

¢Bad surface quality

 

 
J
¢


¢
K

¢
K

 
¢

¢
Wet
 
 
 
 
¢
 
 
 
 

 

¢Wave

 

 
 

¢
K

¢
K
 
 
 
 

¢
K

J
¢



J
¢


 
¢
 
¢
 
 

 

¢Unlevelling side

 

 
 

¢
K

¢
K
 Conventional
milling
 
¢
 
J
¢

J
¢

J
¢

¢
 
 
 
 
 

 

¢Burrs and down edges

 

 
 

¢
K

¢
K
 
 
 
 

¢
K
 
 
 
 
 
 
 
 

 

¢Produce chattering

 

 

¢
K
J
¢

 
 
 
 
 
J
¢


¢
K
J
¢

¢
 
 
¢
¢
¢
Chip removal

 

¢Unsmooth discharge
of chips

 

 
 

¢
K

¢
K
 
¢
 
 
 

¢
K
             

Others

 
When the edge is grinded too much, usually problem like end mill will be damaged and
machining surface's precision is not good etc will happen. We suggest sharpening ASAP.

Shortening the edge length of end mill to the utmost within the allowed range, and improving
machine tools' installation rigidity, precision, are efficient solution to any problem.