Milling Cutters

  1. What are the different forces taking place on milling cutters and explain them.
    Axial - going into the spindle. Radial - on the side. Tangential - tries to stop cutter from spinning
  2. Climb Milling
    Used on CNC machines. Also called down milling. Chip is thick to thin. Not recommended on manual machines.
  3. Conventional Milling
    Used on conventional machines. Also called up milling. Chip is thin to thick. Not recommended on CNC machines unless there is no other option.
  4. 90° Shoulder Facemill
    Square shoulders/ Think walled Workpieces/ High Radial Forces 
  5. 45° Facemill
    General purpose for flat surfaces/Maximum feed per tooth/ Chip thinning/Balanced Radial and Axial forces
  6. 75° Facemill
    Thins the chip slightly/ For when a 45° cutter has insufficient fixture clearance/ Reduced radial forces
  7. Variable Pitch/ Helix Endmill
    Reduces harmonics/ stops chatter and vibration
  8. Slot Mills/ 2 Flute Endmills
    End cutting/ plunge cuts/ stronger flutes/ centre cutting
  9. Double Ended Endmills
    Cheaper/ Lighter Cuts
  10. Ball Nose Endmills
    Produces Precise Radii on part/ Mould Making/ Solid carbide or Indexable (steps)
  11. Roughing Endmills
    Coarse or Fine pitch/ free cutting/ leaves ribbed finish
  12. HSS Shell Mill
    Interchangeable heads
  13. Grooving Cutters
    Various Insert Widths available/ Interpolates ID or OD grooves
  14. Tang Mill Style Facemill
    Multiple insert corners/ tangential forces/ tang mill style
  15. PCD Aluminum Facemill
    Aluminum body made lighter for higher rpm/ Poly Crystaline Diamond
  16. Rotary Milling Cutter
    Each cutting edge spins on a bearing/ should cause even wear on each cutting edge
  17. Face and Side Cutting 
    Slots and Grooves
  18. Roughing Endmill (Porcupine Cutter)
    High metal removal/ multiple inserts/ leaves rough finish/ not end cutting
  19. Endmills
    Used for removing material from the top or sides of a work piece/ 2,3,4,6,8 teeth/ some endcutting/ limited depth of cuts/ more precise/ various ground radii possible/ regrindable/ long cut length on walls
  20. Slitting Saws
    for producing very thin slots
  21. Dovetails and T-slot cutters
    for making dovetail shapes and woodruff keyseats
  22. Special Radius Cutter
    produces a corner radius at a customer specified size
  23. Tailor Made Custom Cutters
    To produce unique profiles/ CNC ground/ Virtually any shape possible
  24. Thread Milling
    Used to make large threaded holes without using a tap
  25. 70% Engagement Rule of Thumb
    2/3 (70%) of the cutter needs to be engaged  in the cut and 1/3 (30%) needs to be out of the cut
  26. Chip formation lead angles
    90 degree creates a big chip/ 45 degrees creates a thinner chip
  27. Coolant in Milling Rules of Thumb
    Never Use Coolant when Milling
  28. Cutter with Round Inserts
    Pros - Robust milling cutters/ very flexible for face milling and profiling/ high performance multi-purpose cutters 

    Cons - round inserts requires more stable conditions 

    Forces - radially/axially/and in between
  29. 45­­ degree face and shoulder mill
    Pros - general choice for face milling/ balanced radial and axial cutting forces/ smooth entry into cut

    Cons - max cutting depth 6-10mm 

    Forces - equal axial and radial forces
  30. 90 degree face and shoulder mill
    Pros - great versatility/ first cutter generating true 90 degree square cuts / light cutting inserts with true four edges 

    Cons - Max cutting depth .157in 

    Forces - only radial
  31. Low Pitch (Coarse pitch)
    Fewer inserts (4)/ lower feedrate/ less vibration
  32. Medium Pitch (Close pitch)
    Double inserts (8) higher feedrate/ more vibration
  33. High Pitch (extra close pitch)
    Inserts further apart, higher stability
  34. How do you prevent vibration in milling?
    Fewer teeth require less HP and induce less axial pressure. Moving the cutter off centre creates less vibration. Differential pitch where the teeth are unevenly distributed around the mulling cutter creates varying frequencies to combat harmonics. 
Card Set
Milling Cutters
Milling Cutters