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Troubleshooting (FAQ)

Selecting the Proper Tool

  1. Select a tool with largest possible cutting die and shortest possible length of cut for maximum rigidity to obtain longer tool life, cycle times and hence productivity.
  2. Select end mills to allow for adequate chip evaluation with as many flutes as possible.
  3. Keep the shortest overhang of the tool from the tool holder as possible to avoid chatter and vibration.
  4. A continuous feed is required to avoid work hardening when working with exotic alloys.
  5. Use cutting feed and speed rates for the particular work piece material and type of machining cuts.
  6. Surface finish can be improved by reducing feed rates but should not be too low as it will tend to rub but not cut effectively.
  7. Higher feed rates can be used when surface finish is not important remembering that too larger chipload can cause breakage.
  8. If the machine is overloaded due to lack of horse power it is preferable to decrease width and depth of cut instead of decreasing table feed.

Did You Know?

“Minicut” style, series 995 end mills for titanium re manufactured to the nas 986 specification from premium 8% cobalt, which achieves a superior edge wear resistance and hot hardness?

Have drawn shanks in sizes over 3/8 “ diameter for maximum shock absorbtion in heavy cuts?

Have 35-degree helix angles, and postive radial rake for maximum cutting \ shear action, with minimum edge surface contact, reducing the heat load at the cut?

Virtually eliminate chip build up in pocketing applications because of their unique chip formation and evacuation design?

Substantially reduce chatter in heavy cuts and thin wall applications because of an uneven spaced flute design?

Continually produce a surface finish of 125 rms, not the 250 to 500 rms of conventional cutters, possibly eliminating the time consuming process of a finishing pass?

Are radius compatible?

And, they also perform exceptionally well in stainless steel applications because of their inherent design characteristics.

What does popcorn have to do with precise, fast, efficient machining of titanium????

Too many old maids slowing your machining operations???????

Deep pocket parts collect chips that result in extremely slow feed rates, vibration and chatter.

Minicut international’s #995 titanium geometry end mills form Popcorn style chips.

Popcorn chips float to the surface allowing you to flush deep parts without special apparatus.

“minicut” style end mills’ innovative engineering provides superior metal removal rates, excellent surface finish and are chatter and vibration free.

For example, if you re-cut one 6al-4v chip, you double the rockwell hardness, making the chip harder than the cutting tool. This makes for extremely slow and costly feed rates.

Minicut international inc.

Pop one into your spindle.

What should I do if I have a problem with ...

ChatteringFeed & speed too fastAdjust feed & speed.
Lack of rigidityUse better machine, tool holder and fixturing.
Lack of reliefDecrease relief angle, grind margin.
Poor set-upImprove clamping rigidity.
Too heavy a cutDecrease width and depth of cut.
Too much overhangUse shorter tool, hold shank deeper
Poor FinishExcessive feed rateReduce feed rate.
Cutting speed is too lowIncrease RPM.
Too much usageRegrind at earlier stage.
Recutting chipsEvacuate chips with coolant or air pressure and change feed & speed.
No end tooth concavityGrind dish angle at end of teeth.
BreakageHeavy feedReduce feed rate.
Heavy cutsDecrease width and depth of cut.
Too much overhang of toolUse shorter end mill.
Too much wearRegrind at earlier stage.
Wear Excessive cutting speed Decrease RPM.
Work material is too hardUse premium grade tool material and coated tools.
Recutting chipsChange feed & speed clear chips with coolant or air pressure.
Feed rate too slowIncrease feed rate.
Improper helix and tool geometryChange tools to correct helix and geometry recommended for the work material.
Chip packingToo heavy a cutDecrease width and depth of cut.
Not enough chip spaceUse end mill with less flutes.
Not enough coolantUse high pressure coolant and direct to point of cut.
ChippingExcessive feed rateReduce feed rate.
Lack of rigidityUse better machine or tool holder, and use shortest end mill available.
Tool cutting angle and corners too sharpDecrease rake angle primary relief and use chamfered or radius corners.
BurrsToo much wearReduce radial width of cut.
Regrind at earlier stage.
Work material too softCorrect cutting parameters and helix angle of tool.
Deflection of side wallFeed rate heavyReduce feed rate.
Too much overhang of toolUse sharper end mill, hold shank deeper.
Too few flutesUse multiple flute end mills with more rigidity.
No dimensional accuracyToo heavy a cutDecrease width & depth of cut.
Lack of accuracy (machine holder)Calibrate machine and holder.
Not enough rigidityChange machine or tool holder or cutting parameters.
Too few flutes Use multi flute end mills with high rigidity.
Short tool lifeToo much cutting frictionRegrind often.
Work material too hardUse better grade tool material and coatings.
Improper helix and primary reliefChange tools to correct helix.