- 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.
- Select end mills to allow for adequate chip evaluation with as many flutes as possible.
- Keep the shortest overhang of the tool from the tool holder as possible to avoid chatter and vibration.
- A continuous feed is required to avoid work hardening when working with exotic alloys.
- Use cutting feed and speed rates for the particular work piece material and type of machining cuts.
- 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.
- Higher feed rates can be used when surface finish is not important remembering that too larger chipload can cause breakage.
- 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.
“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 ...
| PROBLEM | CAUSES | SOLUTION |
|---|---|---|
| Chattering | Feed & speed too fast | Adjust feed & speed. |
| Lack of rigidity | Use better machine, tool holder and fixturing. | |
| Lack of relief | Decrease relief angle, grind margin. | |
| Poor set-up | Improve clamping rigidity. | |
| Too heavy a cut | Decrease width and depth of cut. | |
| Too much overhang | Use shorter tool, hold shank deeper | |
| Poor Finish | Excessive feed rate | Reduce feed rate. |
| Cutting speed is too low | Increase RPM. | |
| Too much usage | Regrind at earlier stage. | |
| Recutting chips | Evacuate chips with coolant or air pressure and change feed & speed. | |
| No end tooth concavity | Grind dish angle at end of teeth. | |
| Breakage | Heavy feed | Reduce feed rate. |
| Heavy cuts | Decrease width and depth of cut. | |
| Too much overhang of tool | Use shorter end mill. | |
| Too much wear | Regrind at earlier stage. | |
| Wear | Excessive cutting speed | Decrease RPM. |
| Work material is too hard | Use premium grade tool material and coated tools. | |
| Recutting chips | Change feed & speed clear chips with coolant or air pressure. | |
| Feed rate too slow | Increase feed rate. | |
| Improper helix and tool geometry | Change tools to correct helix and geometry recommended for the work material. | |
| Chip packing | Too heavy a cut | Decrease width and depth of cut. |
| Not enough chip space | Use end mill with less flutes. | |
| Not enough coolant | Use high pressure coolant and direct to point of cut. | |
| Chipping | Excessive feed rate | Reduce feed rate. |
| Lack of rigidity | Use better machine or tool holder, and use shortest end mill available. | |
| Tool cutting angle and corners too sharp | Decrease rake angle primary relief and use chamfered or radius corners. | |
| Burrs | Too much wear | Reduce radial width of cut. |
| Regrind at earlier stage. | ||
| Work material too soft | Correct cutting parameters and helix angle of tool. | |
| Deflection of side wall | Feed rate heavy | Reduce feed rate. |
| Too much overhang of tool | Use sharper end mill, hold shank deeper. | |
| Too few flutes | Use multiple flute end mills with more rigidity. | |
| No dimensional accuracy | Too heavy a cut | Decrease width & depth of cut. |
| Lack of accuracy (machine holder) | Calibrate machine and holder. | |
| Not enough rigidity | Change machine or tool holder or cutting parameters. | |
| Too few flutes | Use multi flute end mills with high rigidity. | |
| Short tool life | Too much cutting friction | Regrind often. |
| Work material too hard | Use better grade tool material and coatings. | |
| Improper helix and primary relief | Change tools to correct helix. |