Technical Guidance Troubleshooting for Milling
■ Troubleshooting for Milling
Failure
Basic Remedies
Countermeasure Examples
Excessive Flank Wear Tool Grade
· Recommended Insert Grade
· Select a more wear-resistant grade
(
P30 → P20 → Coated K20 → K10 Cermet ){
Steel
Cast Iron Non-Ferrous Alloy
Carbide
T250A, T4500A (Cermet) ACP100 (Coated) ACP2000
ACK100 (Coated) BN7000 (SUMIBORON) ACK200 (Coated) ACK2000
Finishing
DA1000 (SUMIDIA)
Cutting Conditions
· Decrease the cutting speed · Increase feed rate
Roughing
DL1000 (Coated)
· Recommended Insert Grade
Excessive Crater Wear
N
Tool Grade Tool Design Cutting Conditions
· Select a crater-resistant grade · Use a sharp chipbreaker (G → L) · Decrease the cutting speed · Reduce depth of cut and feed rate
Steel
Cast Iron Non-Ferrous Alloy
T250A, T4500A (Cermet)
Finishing
ACK100 (Coated) DA1000 (SUMIDIA)
Roughing ACP100 (Coated) ACK200 (Coated) DL1000 (Coated)
Chipping
· Recommended Insert Grade
Tool Grade
· Use a tougher grade P10 → P20 → P30 K01 → K10 → K20
Steel
Cast Iron
Finishing ACP200 (Coated)
ACK200 (Coated)
Tool Design
· Select a negative/positive cutter with a large peripheral cutting edge angle (a small approach angle). · Reinforce the cutting edge (honing) · Change chipbreaker (G → H) · Reduce feed rate · If it is due to excessive low speeds or very low feed rates, select a grade resistant to chip adhesion · If the cause is thermal cracking, select a thermal impact resistant grade · Select a negative/positive (or double negative) cutter type with a large peripheral cutting edge angle (a small approach angle) · Reinforce the cutting edge (honing) · Change chipbreaker (G →→ H) · Increase insert size (thickness in particular) · Select appropriate conditions for that particular application · Select an adhesion-resistant grade Carbide → Cermet · Improve axial runout of cutting edges Use a cutter with less runout Mount the correct insert · Use a wiper insert · Use cutters dedicated for finishing · Increase the cutting speed · Select a cutter with sharp cutting edges · Use an irregular pitched cutter · Reduce the feed rate · Improve the rigidity of the workpiece and cutter clamp ( )
Roughing ACP300 (Coated)
ACK300 (Coated)
· Recommended cutter: WaveMill WGX Type · Cutting conditions: Refer to H20
Cutting Conditions
· Recommended Insert Grade
Breakage
Tool Grade
Steel
Cast Iron
ACP300 (Coated) ACP3000
ACK300 (Coated) ACU2500
Roughing
Tool Design
· Recommended cutter: WaveMill WGX Type
· Insert thickness: .125 → .187” · Change chipbreaker: Standard → Strong edge type
Cutting Conditions
· Cutting conditions: Refer to H20
· Recommended Cutters and Insert Grades
Tool Grade
Unsatisfactory Machined Surface Finish
Steel
Cast Iron Non-Ferrous Alloy
Tool Design
WGX Type* ACP200 (Coated) WGX Type T4500A (Cermet)
DGC Type ACK200 (Coated)
RF type * H1 (Carbide) DL1000 (Coated Carbide)
Cutter Insert
FMU Type BN7000 (SUMIBORON)
RF Type DA1000 (SUMIDIA)
Cutter Insert
Cutting Conditions
Cutters marked with * can be mounted with wiper inserts.
Tool Design
Chattering
· Recommended cutter For steel: WaveMill WGX Type For cast iron: Sumi Dual Mill DGC Type For light alloy: Aluminum Body Cutter RF Type
Cutting Conditions Others
Tool Design · Select a cutter with good chip evacuation features · Reduce number of teeth · Enlarge chip pocket
Unsatisfactory Chip Control
· Recommended cutter: WaveMill WGX Type
· Increase the peripheral cutting edge angle (decrease the approach angle) · Change chipbreaker (G → L) · Reduce the feed rate
Tool Design
· Recommended cutter: WaveMill WGX Type
Edge Chipping On Workpiece
Cutting Conditions
· Recommended cutter: W aveMill WGX Type + FG Chipbreaker Sumi Dual Mill DGC Type + FG Chipbreaker
Burr formation
Tool Design Cutting Conditions
· Use a sharp cutter · Increase feed rate · Use a burr-proof insert
N56
Made with FlippingBook flipbook maker