Milling solutions
| MILLING SOLUTIONS | ||
| Problem | Cause | Solutions |
| 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 |
| 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 |
| Tool breakage | • Machining cross-section is too large • Feed rate is too high • Tool is too long |
• Reduce or adjust feed rate per tooth • Reduce feed rate • If possible, choose the quickest possible process |
| Poor surface quality | • Incorrect tool chosen • Incorrect lubricating coolant delivery • Feed rate is too high • Rotation rate too low • Built-up edge development • Chip removal not at optimum • Chips too large • Tool wear |
• Adjust tool to the work • Ensure correct lubricating coolant delivery • Reduce feed rate • Increase rotation speed • Use tools with a greater twist angle • Optimize lubricating coolant delivery • Reduce machining cross-section • Replace or re-sharpen tool in good time |
| Chatter marks on the surface | • Tool run-out error • Tool not stable • Tool clamp unstable |
• Reduce run-out error • Use a tool with a larger shaft • Check the clamping device or replace |
| Extreme flank wear | • Machining temperature too high • Incorrect cutting material chosen |
• Reduce cutting speed • Choose a tool made from a suitable cutting material |
| Too much tool wear | • Incorrect cutting specifications • Incorrect twist angle • Conventional milling • Incorrect tool |
• Match cutting specifications to the work • Select a tool with the correct twist angle • Use tool in synchronism • Adjust tool to the work |
| Lengthways markings on the surface | • Break-outs at the borehole boundary surface | • Replace tool |
| Extreme crater wear | • Cutting pressure too high • Machining temperature too high |
• Reduce feed rate • Reduce cutting speed |