IIn this section we mention some of the more popular problem related to the milling operations. Very often the careful analysis of the process, the tool and the machined surface of the chip product allows to act in order to solve problems or to optimize the use of the tool. We underline how the cost of processing depends heavily on the life of the tool, the finishing, the reduction of the waste and downtime for controls, settings and tool changes. We are convinced that a careful selection of the tool is one of the essential process to have a good productivity.
Here below is a list of typical problems that occur during a milling operation.
edge chipping
Possible corrective actions
- Decrease feed per tooth
- Increase the cutting speed
- Cutter with carbide too fragile, change with carbide tougher
- Check rigidity of the machine
- Check run-out of the cutter
- Ensure appropriate choice of cutter geometry
- Difficulties in the evacuation of the chip: please test the cutter path or direction and pressure of the refrigerant
tool wear
Possible corrective actions
- Reduce the cutting speed
- Increase feed per tooth
- Cutter with carbide material of low resistance to wear, please use carbide with most features of wear resistance
- Ensure appropriate choice of cutter geometry
- Ensure appropriate choice of the coating
Edge cratering
Possible corrective actions
- Reduce the cutting speed
- Decrease the feed per tooth
- Cutter with carbide material of low resistance to wear, please use carbide with most features of wear resistance
- Increase the flow/pressure refrigerant
- Ensure appropriate choice of the coating
Up edge
Possible corrective actions
- Decrease the depth of cut
- Increase the cutting speed
- Increase feed per tooth
- Increase flow/pressure refrigerant
Poor work piece surface
Possible corrective actions
- Decrease feed per tooth
- Decrease the depth of cut
- Increase the cutting speed
- Check the rigidity of the machine
- Use a cutter with helix angle sharper
- Use a cutter with greater number of cutting edges
- Check the run-out of the cutter
Presence of vibration during machining
Possible corrective actions
- Decrease the depth of cut
- Reduce the cutting speed
- Check the stability of the machine
- Check the stability of the piece
- Check the refrigerant density
- Use an end mill with more teeth
- Use a shorter cutter
- Use a cutter with irregular division
- Decrease the rake angle
Presence of chips on the piece
Possible corrective actions
- Decrease feed per tooth
- Decrease the depth of cut
- Decrease the phase of the cutting edge
Overload the machine
Possible corrective actions
- Reduce the cutting speed
- Decrease feed per tooth
- Decrease the depth of cut
Do not perpendicular wall
Possible corrective actions
- Check the concentricity of the cutter on the machine
- Reduce the cutting speed
- Decrease depth and width of cut
- Decrease the total length
- Use cutter with more teeth
No dimensional accuracy
Possible corrective actions
- Decrease depth of the cutting pass
- Improve the rigidity of the spindle and the clamp
- Use cutter with more teeth
Chip forming ball
Possible corrective actions
- Reduce feed or speed
- Use cutter with less number of teeth
- Increase the flow of the refrigerant
- Try different geometries of the cutting edge
Flash
Possible corrective actions
- Anticipate regrinding
- Correct the parameters and the cutting angle
Broken cutter
Possible corrective actions
- Reduce speed and feed per tooth
- Use a shorter cutter
- Anticipate regrinding
- Check the spindle
- Check the run-out
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