Application indications and solutions for milling
|
Problem |
Cause |
Solution |
|
Vibrations on the milling cutter |
• Cutting speed is too high • Feed rate is too low • Tool clamping is not unstable • Tool is too long • Tool is too unstable • Flute length too great |
• Reduce cutting speed • Increase feed rate • Check the clamping device or replace • If possible, choose the quickest possible process • Use a stronger shaft • If possible, choose the quickest possible process |
|
Vibrations on the workpiece |
• Clamping is not stable enough |
• Check tool clamping and optimize if appropriate |
|
Cutter breakage |
• Tool wear • Incorrect cutting specifications • Vibrations • Conventional milling • Tool stability • Workpiece stability |
• Replace or re-sharpen tool in good time • Match cutting specifications to the work • Reduce rotation speed • Mill in synchronism • If possible, choose the quickest possible process • Check clamping device and optimize if appropriate |
|
Breakage of the cutting edge |
• Tool stability • Workpiece stability • Vibrations • Feed rate is too high • Conventional milling • Cutting material too brittle • Incorrect tool |
• If possible, choose the quickest possible process • Check clamping device and optimize if necessary • Reduce rotation speed • Reduce feed rate • Mill in synchronism • Replace with a tool made from a higher quality cutting material • Select the tool according to the work |
|
Milled slot is too small less than the diameter of the tool |
• Too much tool wear |
• Replace or re-sharpen tool in good time |
|
Milled slot is too large less than the diameter of the tool |
• Tool run-out error |
• Minimize run-out error |
|
Service life is too short |
• Reaming is too intense • Incorrect tool chosen • Incorrect front rake angle • Lip clearance of the tool is incorrect |
• Use a coated tool • Adjust tool to the work • Select a tool with the correct front rake angle • Correctly grind or re-sharpen the tool |