Selection and Applications

Milling

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 Milling
Cutter
Selection
M
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a me n
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hin p rt an
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Ma Set-u Ins rad on
& G cti
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In
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 Evaluate the Workpiece Print
• Features
• Stock
• Material
• Hardness
• Rigidity
• Dimensions R

• Tolerance
• Finish
• Quantity

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 Face Milling
• Material 4140 steel
• Hardness 200BHN
• D.O.C. .125(3.175mm)
• Finish 125 AA
• Tolerance+ or - 0.005(0.127mm) thickness
• Machine CNC vert. mill, automatic
tool changer 5”(127mm) max. dia.
• H.P. 25 at the spindle
• Workholding Vise
• Quantity 200 per month, 2,400 yearly
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 Choosing a Face Mill

• Diameter
• Lead Angle
• Pitch
• Hand
• Geometry
• Adapter/Mounting

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 Cutter Diameter

• 3:5 workpiece-to-cutter diameter

ratio
(or 1.5 times the workpiece width)

4” (101.6 mm)

6 inch (160mm) or 3
(80mm) inch cutter?

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 Lead Angle
0° Lead 15° Lead

30° Lead 45° Lead

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 Pitch

• Coarse • Fine

• Heavier IPT • More Teeth Engaged

• Larger Gullets • More IPM
• Larger DOC’s • Lighter DOC’s
• Least HP • Higher HP
• Fewest Teeth • Less Chip Clearance

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 Pitch — Effect on Feed

500 RPM
.005 IPT
(0.127
mmper
tooth)

• Coarse • Fine
7 Teeth 12 Teeth
x x
.005 IPT (0.127 mm/tooth) .005 IPT(0.127mm/tooth)
x x
500 RPM 500 RPM
= 17.5 IPM (444.5mm/min) = 30 IPM(762 mm/min)
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True Differential Pitch
68°

75°

70°

73°

74°

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 Cutter Hand
LH RH
Less Common More Common

Application Specific General Purpose

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 Geometries
Double Positive Double Negative

(+) (-)

(+) (-)
Shear Angle

(+)

(-)

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 Geometry Variations

High Positive High Shear

„ High Positive Radial „ Neutral or Negative Radial
ΠDiameter Dependent ΠDiameter Dependent
„ High Positive Axial „ High Positive Axial
Œ 20° Positive Œ 20° Positive

„ Features „ Features
ΠAluminum ΠBest General Purpose
ΠFree Cutting ΠMany Workpiece Materials
ΠFragile Edge ΠLow HP required
ΠGood Chip Ejection

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 Double Negative
Advantages
„ Strongest Insert Shape
„ Most Indexes
„ Heavier Feeds
„ Ceramic Applications
ƒ Cast Iron
ƒ Hardened Materials
ƒ Hi-Temp Alloys
(special applications)
Disadvantages
„ Requires the Most
Rigidity
„ Chip Flow into the
workpieces
„ Chip Re-cutting
„ Highest Cutting Forces
„ Increased Heat
ƒ Lower Tool Life
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 Double Positive

Advantages Disadvantages
„ Low HP consumption „ Not for High Tensile or
„ Good for work Hardened Materials
hardening materials „ Fragile Edges
„ Good for Soft Gummy „ Pulling Forces
Materials

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 Negative / Positive

Advantages Disadvantages
„ Best Chip Ejection „ Fewer Cutting Edges
„ Best General Purpose than double negative
„ Recommended for Most
Workpiece Materials
„ Balanced Cutting Forces

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 Shoulder Milling

HSS Carbide Indexible

End Mill End Mill End Mill
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 HSS End Mill

Advantages Disadvantages

Free Cutting Must be Reset After

Resharpening
Economical
Initial Purchase HSS Speeds and
Feeds
Regrindable
Difficult to
Accommodate
Various Corner Radii

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 Carbide End Mill

Advantages Disadvantages
„ Minimal Deflection „ High Initial Price
Long Tool Life
„ Costly to Regrind
„ Higher Speeds

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 Inserted End Mill

Advantages Disadvantages
„ Run at Coated „ Fewer Effective
Carbide Speeds Flutes
„ No Need for „ Insert Overlap
Regrinds Creates Blend
Marks
„ Multi corner radii
available „ Difficult to
produce
special forms

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 Inserted End Mill

„ Feed Rate is
based upon the
number of
effective flutes
(teeth) in the
cutter

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Half Effective Helical End Mill

INDUSTRY STANDARD
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All Effective Helical End Mill

KENNAMETAL Helical Endmills

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Indexable Helical End Mill

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 Channel Milling

HSS Solid Carbide Indexable

End Mill End Mill End Mill
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Indexable End Mill

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Cutter Selection — Slotting

Depth

Finish

Radius

Width
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Cutter Selection - Slotting

HSS Indexable
Slotting Cutter Slotting Cutter

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 Cutter Selection —
Slotting Cutter Mounting
Minimum

Minimum

Minimum

Arbor Mounted
Adaptor Mounted

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 Cutter Selection —
HSS Slotting Cutter
Advantages
ƒ Lower Initial Cost
ƒ Can be Ground for Special
Widths and Radii Requirements
ƒ Finer Pitch Available

Disadvantages
Radius
ƒ Must be Reground
(Decreasing Width and
Diameter)
ƒ Throw Away
ƒ HSS Speeds and Feeds

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 Cutter Selection —
Indexable Slotting Cutter
Advantages
„ One Cutter Body for Various
Widths and Radii
„ Runs at Carbide Speeds
„ Indexable - No Regrinding
(Replaceable Hardware)
„ Grades to Optimize for Various
Materials Disadvantages
„ Fixed and Adjustable Widths
„ Higher Initial Price
„ Generally Requires More H.P.
„ Fewer Teeth
„ Will leave a “Witness” mark
in the bottom of slot

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Cutter Selection Slotting

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Cavity Milling

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 Cavity Milling

Center-Cutting HSS Ball Nose Ramp and

End Mill End Mill Plunge Mill (RPF)

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Cutter Selection —
Cavity Milling

Drilled Access Hole-

Common Cutter Path Will Not Be Flat Bottomed

Multiple Passes to Generate

Rough Cavity or Full Depth of Cut
to Rough Cut Cavity

Center Cut End Mill Access

Hole Flat Bottomed
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 Cutter Selection —
Cavity Milling, C.N.C. Machine

PLUNGE
& FEED HELICAL
RAMP Z INTERPOLATION

C° ramp
angle

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Cavity Milling

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38
 Milling Cutter Selection

• Evaluate Everything About the Workpiece

• Evaluate Each Operation Being Performed
• Determine Cutter by Making Decisions About:
– Cutter Diameter
– Lead Angle
– Pitch
– Hand
– Geometry
• Fundamentals are the Foundation

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 Insert and
Grade
Selection
M
Fund illing
a me n Ap Mill
tals pli ing
ca
tio
ns
e g
chin p i llin er
Ma Set-u M tt n
& Cu ctio
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n Se
ctio
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rod
Int
Opt
Tr Perf imizing
ou orma
ble nce
sh
o oti
n g

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Insert and Grade Selection

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 Strength by Shape

Strongest Weakest

Round Octagon Square Parallelogram Triangle

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Corner Configuration

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 The Ideal Cutting Point
Combines
• Toughness

• Heat Resistance

• Edge Wear
Resistance

• Thermal Shock Resistance

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 Edge Preparation
Sharp Edge Honed Edge
Cutting forces Cutting forces

T-Land Edge T-Land Edge With Hone

Cutting forces Cutting forces

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 Rake Face Contours

GB GP LD
5° rake face angle 11° rake face angle 15° rake face angle

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 Milling ‘M’ Grades
KC930M KC915M

KC725M KC920M

KC792M KC925M

KYON 3500

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 Chips

Continuous Broken

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Steel Machining
- -

other
alloys

WC Co

+ +
Wear and Strength
Thermal Shock
Resistance

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Cast Iron Machining

- -

WC Co

+ +
Wear and Strength
Thermal Shock
Resistance

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 Substrates and Coatings
- carbide substrate and
multi-layer PVD coating
- steel and stainless steel
applications
KC725M
- carbide substrate and CVD
alumina (ceramic) coating
- gray cast iron applications
KC920M

- carbide substrate and - carbide substrate and CVD

CVD/PVD coating alumina (ceramic) coating
- higher speed steel - nickel-base alloy and
KC792M applications KC925M ductile iron applications

- ultra-pure silicon nitride

substrate
- high-speed cast iron
Kyon 3500 applications

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 Cermet
Operational Range
1200 (366)

1000 (305) plain carbon steel

speed (sfm)
800 (244) low carbon,
low alloy steel
KT19
5M
600 (183)

(122) Stainless
400
steels

200 (61)

(0.05) (0.1) (0.15) (0.2) (0.25) (0.3) (0.35)

.002 .004 .006 .008 .010 .012 .014

chip load per tooth (in)

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Ceramic (Alumina Based)
4,000
(1220)

speed – SFM (m/min)

3,000 Gray Cast Iron
(915)
Plain Carbon Steel

wear
180-240 BHN
2,000
(610)
Haynes Alloys Stellite

1,000
(305)
Alloy Steel 450-700 BHN & Tool Steel
(0.1) (0.2) (0.31) (0.41)

.004 .008 .012 .016

Toughness
Feed – IPT (mm/Tooth)

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Ceramic
Ceramic (Silicon
(Silicon Nitride
Nitride Based)
Based)
Kyon
Kyon 3400
3400 // Kyon
Kyon 3500
3500
4,000 (1200)

speed – SFM (M/MIN)

3,000 (915)
Gray Cast Iron

wear
2,000 (610)

Ductile and Malleable

Cast Irons
1,000 (305)

(0.1) (0.2) (0.3) (0.4)

.004 .008 .012 .016

Toughness
Feed – IPT (mm/Tooth)

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Polycrystalline
Polycrystalline Diamond
Diamond (PCD)
(PCD)
KD1410
KD1410
10,000 (3050)

speed – SFM (M/MIN)

7,500 (2288) Aluminum

wear
5,000 (1525)

High Silicon
Aluminum
2,500 (763)

(0.1) (0.2) (0.3) (0.4)

.004 .008 .012 .016

Toughness
Feed – IPT (mm/tooth)

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Polycrystalline
Polycrystalline Cubic
Cubic Boron
Boron
Nitride
Nitride (PCBN)
(PCBN)
1,500
(457.5)

speed – SFM ( M/MIN)

1,000

wear
(305)
White Chilled Iron
480-650 BHN
Tools Steels
510-750 BHN
500
( 152.5)

(0.1) (0.2) (0.3) (0.4)

.004 .008 .012 .016

Toughness
Feed – IPT (mm/tooth)

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 Comparison Graph
PCD
Wear Resistance

(Speed)

CBN
Tic Alumina Ceramic Alumina Zirconia Ceramic
Cermet
Sialon & Silicon Nitride Ceramic

CVD Alumina Coated Carbide PVD

Coated
CVD Tri-Phase Coated Carbide Carbide

Uncoated Carbide

High Speed Steel

Strength (Feed)
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 Factors that Affect Speed

• Workpiece Hardness
• Workpiece Condition
– Scale
– Sand
• Condition of the Machine
• Horsepower Available
• Ability of the Grade to withstand Heat
(Hot Hardness)

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 Factors
Factors Affecting
Affecting Feedrates
Feedrates
(mm/rev)
(mm/rev)

• Machine Horsepower
• Machine Rigidity
• Fixture Rigidity
• Positive vs. Negative Geometry
• Cutter Pitch
• Surface Finish Required

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 Factors
Factors Affecting
Affecting Depth
Depth of
of Cut
Cut
(DOC)
(DOC)

• Machine Horsepower

• Machine Rigidity

• Fixture Rigidity

• Material to be Removed

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 Experience Teaches Us to
Consider These Elements:
• Workpiece Material - Composition and
Hardness
• Condition of Workpiece Material - Forged,
Cast, Hot Rolled, Cold Drawn
• Type of Machining or Type of Cut
• Condition of Machine Tool
• Type of Production - Long or Short Run

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 Insert and Grade Selection

• Combine Technical Data with your

Experience
• Insert Selection
– Strength by Shape
– Edge Preparation
– Rake Face and Clearance Angles
• Cutting Tool Material Selection
– Match the Grade, with the Workpiece Material
and the Operating Conditions

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 Milling
Applications

Millin
g
Cutte O
Selec r Pe ptim
tion rfo iz
rm ing
an
ce

hine t a nd
c p er e
Ma Set-u Ins rad on
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M
Fund illing
Tr
ou
a me n
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sh
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 Face Mill Application Tips
• Requires two Passes
• 1/4 to 1/3 Cutter
Overhang
• Climb Milling
• Negative Angle of Entry
Workpiece
• Avoid Full Cutter Feed
Engagement
• Use Lead Angle
Geometry Whenever Cutter
Possible Overhang

• Select Pitch that Keeps Cutter Position

Two Teeth Engaged in
Work
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 Face Mill Application Tips

• Offset Cutter 9” Diameter

Slightly from Cutter

Centerline
– Less Chance
of Chatter
– Good Chip
Thickness Workpiece

at Entry and 6”
Exit
Cutter Position

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 Face Mill Application Tips

Positive Angle
of Entry

Neutral Angle
of Entry

Constantly Changing Angle of Entry Negative Angle

of Entry

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Indexable End Mill Application Tips

• Maximize Chip Evacuation

– Air Blast
– High Pressure Coolant
• B.U.E. Resistant Grades
• Rigid Tool Holding
• Concentric Tool Holding
• Climb Cut if Applicable
• Usually Roughing Cutter
• Do not Exceed
Recommended Cutter Depth
• Must Calculate Feed Using
Number of Effective Flutes

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 Cavity Milling Application

• Ramping Preferred to
Plunging
• Helical Interpolation
Preferred to Both
Ramping and Plunging
• Rigid Tool Holding and
Work Holding Desirable
• Maximize Chip
Evacuation
• Adhere to Suggested Feed, Speed, D.O.C.,
and Ramping Recommendations
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 Z-Axis Plunge Milling Cutters

• Increases productivity
through high metal
removal rates in deep
pocket milling while
maintaining rigidity
• Positive geometry
delivers free-cutting
action on a variety of
materials S SS CI NF HT HM
• Z - Axis (axial) feed
direction only
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 Z-Axis Application
END MILLS - Z AXIS MILLING

z-axis
existing
(axial)
access hole
feed
only

entry from
scalloped edge of
surface part
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 Surface Finish
Radius vs Flats vs Wipers
Insert Corner Generated Surface (60AA) 6” (160mm)
Configuration Diameter, 382 rpm

corner radius Ex. SPCW Style 3 ipm (76.2 mm/min)

facet Ex. SEHW Style 11 ipm (279.4 mm/min)

Large
Radius

wiper radius Ex. SEHW-W 47 ipm (1193.8 mm/min)

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KSSM 45 Wiper

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 Measuring Surface Finish
Traditional Method

.100 Length

Preferred Method

feed direction .010 Length

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Milling Applications

The Magic is
in the
Application

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