Measures to eliminate machining faults of end mill

Fault
Occurrence situation
Measures
Tools breaking (when
using solid small
-diameter and brazing
small-diameter
end mill)

When the tools cuts in a work piece

When the tools is pulled out

Reduce feed

Reduce overhanging volume

Shorten the cutting edge length to the minimum limit of necessary length
When the tool is
machining normally
Reduce feed

Wear control replace tools as early as possible

Replace fixture or spring collet

Reduce overhanging volume of the tools

Make passivation treatment to the tools

If using 4-flute end mill, change it to 3-flute or double-flute mill
(prevent chip jamming)


Change dry milling to wet milling (using cutting fluid). When wet milling supplies the fluid from front,
change it to be supplying from back or cross upper side. The flow of cooling fluid shall be sufficient
When feed direction changes
Use arc interpolation (NC machine tool), or halt

Reduce the feed before and after direction change

Replace fixture or spring collet
Chipping
Chipping at tools point
Use manual regrinding to chamfer at corner part

Change climb milling to conventional milling
Damage in cutting depth interface
Change climb milling to conventional milling

Reduce milling speed
Chipping is distributed in
central part or in the whole
cutting edge
Make passivation chamfering or enlarge chamfering

Change rotation of spindle (when the machine tool is vibrating)

Increase milling speed

When there is friction sound during milling, increase feed

If applying dry milling, change it to wet milling or use air to cool

Replace fixture or spring collet

Reduce cutting speed
Large chipping of cutting edge
Reduce feed

If using 4-flute end mill, change it to 3-flute or double-flute end mill

Make passivation chamfering or enlarge chamfering

Replace fixture or spring collet

[when using solid end mill]

Reduce milling speed

If applying dry milling, change it to wet milling. When wet milling supplies the
fluid from front, change it to be supplying from cross upper side or back. The flow
of cooling fluid shall be sufficient.[when using brazing end mill]

If applying wet milling, change it to dry milling, using compressed air. When air is supplied
from front, change it to be supplying from back or cross upper side. Its flow shall be sufficient

In steel's slot milling, with standard cutting condition as target value, select appropriate milling
speed (at low milling speedIt will produce low speed damage, and pressing object will split
and be damaged.) (at high milling speed Chips will jammed and it will produce thermal
cracking while milling deep slot
Early wear of tools
Reduce milling speed

If it is conventional milling, change it to climb milling

Increase feed

Adopting wet or compressed air cooling milling

If using regrinding end mill, improve roughness of back