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Chapter 28

(ote the start position (S) and the end position ()) in the t#o illustrations. They are indicated by the heavy dot at the center of cutter. *egardless of the cutting method, the face milling cutter is al#ays in a clear position at the start and end of cutting, mainly for safety reasons.

Multiple Face Mill Cuts

The general principles applying to a single face cut do apply equally to multiple face cuts. Since the face mill diameter is often too small to remove all material in a single pass on a large material area, several passes must be programmed at the same depth. There are several cutting methods for a large area to be face milled and each may produce good machining conditions under certain circumstances. The most typical methods are multiple unidirectional cutting and multiple bidirectional cutting (called zigzag) - at the same Z depth.
Multiple unidirectional cuts start from the same position in one a is, but changes the position in the other a is, above the part. This is a common method of face milling, but it lac!s efficiency, because of frequent rapid return motions.

Multiple bidirectional cuts, often called zigzag cutting, are also used frequently" they are more efficient then the unidirectional method, but cause the face mill to change the climb milling method to the conventional method and vice versa. This method may #or! for some $obs, but is not generally recommended. %n the ne t t#o illustrations, Figure 28-8 sho#s schematically a unidirectional face milling. Figure 28-9 sho#s a bidirectional face milling.

Figure 28-8/ Unidirectional approach to a multiple face cut for rough and finish face milling

NcKpREA15.IEREP, YgINP tion, a tool path difference (cutter position) bet#een rough

ing and finishing is also shown. The cutting direction may be

either along the & or along the ' a is, but the principles of the cutting motion #ill remain the same.

Figure 28-9 Bidirectional approach to a multiple face cut for rough and finish face milling

There is another fairly efficient method that cuts only in one mode, normally in climb milling mode. This method may remind of a circular or a spiral motion (along the &' a es) and is the most recommended method. %t combines the t#o previous methods and is illustrated in Figure 28-10,

Figure 28-10 Schematic tool path representation for the climb face milling mode applied to a unidirectional cutting

The illustration sho#s the order and direction of all individual tool motions. The idea is to ma!e each cut appro imately the same #idth, #ith only about +,- of the diameter
Figure 28-11 !"ample of a multiple face mill cut - program 02802