CARBIDE TIPPED END MILLS
TECHNICAL INFORMATION
END MILL BASICS

END MILLS: have cutting edges on both the end and sides, permitting end cutting and peripheral cutting. Center cutting types permit plunge and traverse milling.

CUTTING EDGE: Select sharp edged for faster speeds. Select radial edged for longer tool life.

SHANK DIAMETER: Select largest diameter available to maximize rigidity and minimize axial deflection and chatter.

NUMBER OF FLUTES: Select fewer flutes for milling softer materials at higher feeds and speeds where more chip space is required or when machine horsepower is limited.

Select more flutes for milling tougher materials at reduced feeds and speeds or for increased table feeds using the same cutting speeds.

TOOL DIAMETER: Select largest practical diameter to maximize
rigidity, minimize chatter and improve tool life. If machine spindle speed is limited, the largest practical diameter permits higher cutting speeds.

COATINGS: are especially effective (see "Coating Selector"). Stocked coated end mills are available with TiN, TICN, and TIAIN in many sizes.

FLUTE AXIAL RELATIONSHIP:
Select straight flutes for a wide variety of applications.

Select right spiral flutes for improved cutting action and easier chip removal.

Select left spiral flutes for use in absorbing impact shock when entering steel workpiece - maintains constant hold down pressure and minimizes chatter. Useful in profiling applications where recutting chips causes premature cutter dulling.

Select high spiral (15ยบ or more) to dramatically improve cutting action, finish, chip removal, and tool life. High spirals distribute impact load more evenly throughout the tool's entire revolution.

END MILL SPECIFICATIONS & TOLERANCES
  • Geometry, carbide grade, O.D. relief and end clearance appropriate for material being machined
  • Flute long carbide tips brazed to tough hardened alloy steel body
  • Spiral flute carbide tips formed to true helix angles
  • Straight shanks have standard Weldon drive flats
  • Non-center cutting end mills have the ends cleared to depth of carbide
  • Precision ground cutting edges
  • USCTI
  • Tool diameter tolerance:
    Radial edged: plus .002", minus .000"
    Sharp edged: plus .005", minus .000"
  • Shank diameter tolerance:
    minus .0001", minus .0005"
END MILL PROBLEM SOLVING GUIDE - CARBIDE TIPPED
MILLING PROBLEMS POSSIBLE CAUSES POSSIBLE SOLUTIONS
1. ROUGH FINISH Dull cutting edge Resharpen to original tool geometry
Wrong feeds & speeds Increase speed - also try reduced feed
2. EXCESSIVE CUTTING
EDGE WEAR
Wrong feeds & speeds Increase feed (should always be over .001" per tooth) - especially when
machining ductile or free machining materials. Also try reduced speed
Rough cutting edge Lightly hone cutting edge with fine grit diamond hone
Insufficient coolant Increase coolant flow - review type of coolant
3. CHIPPED CUTTING EDGE Poor chip removal Use tool with larger flute space - larger diameter or fewer flutes
Recutting work hardened chips Increase coolant flow
Vibration Increase rigidity of set-up, especially worn tool holders
Incorrect carbide grade Change to tougher carbide grade
4. CHATTER MARKS Insufficient machine horsepower Use tool with fewer flutes as correct feeds & speeds must be maintained
Vibration Consider climb milling
Use larger diameter cutter
Resharpen tool with more clearance
5. GLAZED FINISH Feed too light Increase feed
Dull cutting edge Resharpen tool to original geometry
Insufficient clearance Resharpen tool with more clearance
6. POOR TOOL LIFE Excessive cratering Increase speed or decrease feed
Change to harder grade of carbide
Milling abrasive material Decrease speed and increase feed
Increase coolant flow
Climb milling better than conventional milling
Milling surface scale Conventional milling better than climb milling
Milling hard materials Reduce speed - rigidity very important
Insufficient chip room Use larger diameter tool
Delayed resharpening Prompt resharpening to original geometry will increase tool life
Thermal cracked carbide Maintain adequate coolant flow at all times
Climb milling is cooler than conventional milling