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Endmill’s concept

Endmill’s concept

Cutting speed calculation

Cutting speed calculation

Endmill Regrinding

Endmill Regrinding

Regrinding timing
Range of application Endmill Dia Abrasion loss
Finish machining ~ ø10
ø 11 ~ ø30
ø 31 ~ ø50		 0.05 ~ 0.1
0.1 ~ 0.25
0.2 ~ 0.35
Roughing machining ~ ø10
ø 11 ~ ø30
ø 31 ~ ø50		 0.08 ~ 0.15
0.15 ~ 0.35
0.3 ~ 0.45
Way to regrinding

(1) Concave type
ㆍDemand to close Dia tolerance
ㆍFavorable machinability.
ㆍNeed to 2nd rake Clearance angle

(2) Concave type
ㆍFavorable machinability
ㆍNeed to 2nd rake Clearance angle

(3) Eccentric Type
ㆍFavorable Flute Diameter
ㆍExcellent Surface Roughness on workpiece
ㆍNot necessary for secondary clearance on rake
Honing

Honing
1) Recommended for machining mold steel or high hardness workpiece.
2) When machining without honing, process it for 10 to 30 seconds with
    an slotting of 0.01mm or less before entering the normal speed.

Endmill trouble shooting

Endmill trouble shooting

Troble issue Cause Solution
Broken
  • Excessive feed speed be more than necessary
  • Excessive Depth of cut be more than necessary
  • Excessive protrusion
  • graved flute wear
  • Excessive flue length be more than necessary
  • Reduce feed speed.
  • Reduce Depth of cut
  • Reduce protrusion
  • Regrinding
  • Reduce flute length to the maximum
Wear and burr
  • Excessive cutting speed
  • shortage of rake angle
  • high hardness for workpiece
  • Reduce cutting speed with supply with cutting oil.
  • Modify for rake angle properly
  • Supply with cutting oil and surface treatment below one by one
Vibration during cutting
  • Unsuitable cutting condition
  • Shortage of hardness for machine and chuck
  • Poor fixed for workpiece.
  • Excessive protrusion.
  • Excessive 1st Clearance angle.
  • Modify for cutting speed and feed rate.
  • Change to machine or chuck.
  • Fixed for workpiece solidly.
  • Reduce for cutting length and protrusion length to the maximum.
  • Reduce 1st Clearance angle.
Defection for flute
  • Excessive feed speed be more than necessary
  • Shortage of rake angle.
  • Occur to vibration.
  • Poor fixed for workpiece.
  • Excessive Depth of cut be more than necessary.
  • Excessive protrusion.
  • Shortage of hardness for machine.
  • Reduce feed speed.
  • Modify the angle properly.
  • Reduce the RPM.
  • Fixed for workpiece solidly.
  • Reduce Depth of cut.
  • Reduce protrusion.
  • Change to machine and work.
Bad cutting performance
  • Cutting edge wear.
  • Improper endmill for workpiece.
  • Shortage of rake angle.
  • Regrinding
  • Change to endmill properly
  • Modify for rake angle.
Poor chip emission
  • Shortage for spray pressure or lack of oil level.
  • Small chip pocket.
  • Cutting flute wear
  • Excessive Depth of cut be more than necessary.
  • Increase flow rate and pressure.
  • Use to small flute endmill or reduce feed speed.
  • Regrinding.
  • Reduce Depth of cut
Burr on the surfacce
  • Excessive feed speed be more than necessary
  • Be slow cutting speed
  • Cutting flute wear.
  • Excessive Depth of cut be more than necessary.
  • Reduce feed speed
  • Modify for cutting speed rapidly.
  • Regrinding.
  • Reduce Depth of cut.
Shape faulty
  • Durability fault for machine and chuck.
  • Hardness fault for machine.
  • Over flute length.
  • Lack the number of flute.
  • Repair to machine and chuck.
  • Change to machine and chuck.
  • Modify for flute length properly.
  • Change to endmill with a lot of flute.
Built up edge
  • Lack of affinity between workpiece and tool and shortage of cutting oil
  • Spray to oil below one by one dry > water solubility > non-water-soluble.
  • Active non-water-soluble coolant is suitable when cutting alloy steels.