CARBIDE TIPPED MILLING CUTTERS
TECHNICAL INFORMATION
SLITTING SAWS & SIDE MILLING CUTTER BASICS

ARBOR DIAMETER: Select the largest diameter available to maximize rigidity and minimize deflection. For example, a 1 1/4" arbor is more than twice as rigid as a 1" arbor.

TOOL DIAMETER: For slitting saws, select the smallest diameter which permits the greatest number of teeth to be engaged in the cut at any time.

For slot and side milling cutters, select the diameter which permits no more than two teeth to be engaged in the cut at any time.

NUMBER OF TEETH: Select fewer teeth for low tensile materials and heavier chip loads. Select more teeth for high tensile materials and better finishes.

COATINGS: are especially effective (see "Coating Selector").

APPROPRIATE: carbide grade, carbide finish, number of teeth, flute size, radial rake angle and cutting edge clearance are engineered by HANNIBAL for optimum performance when machining the materials indicated.

TYPES OF MILLING: In conventional milling, the direction of cutter rotation is opposite to the direction of workpiece feed. The initial portion of the chip generated is very thin and gradually increases through the cutting cycle. The maximum cutting force is upward at the end of the cutting cycle.

In climb milling, the direction of cutter rotation and the direction of workpiece feed are the same. The initial portion of the chip generated is thick and gradually thins through the cutting cycle, producing a better finish. The maximum cutting force is the initial downward thrust at the beginning of the cutting cycle.

For deep slotting, HANNIBAL'S saws are appropriate because of adequate side & body clearance.

MILLING CUTTER PROBLEM SOLVING GUIDE - CARBIDE TIPPED

AVOID PROBLEMS BY CAREFUL ORIGINAL SET-UP
MACHINE CONDITION Tool holder in good condition and secure part holding fixture
TOOL CONDITION Use cutting tool recommended for material being machined. Avoid excessive tool overhang.
FEEDS & SPEEDS Start with feeds and speeds recommended for material being machined
COOLANT Coolant flow must be adequate to avoid intermittent quenching and to flush chips promptly, avoiding the recutting of hardened chips.
MILLING CUTTER 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