Fault analysis countermeasures in end mill machining

◆Fault analysis countermeasures in end mill machining

Selection of
tools material

Cutting conditions

Tools profile

Fixture of machine tools

select coated end mill

cutting speed

Feed

cutting depth

cutting direction

Cutting fluid

helical angle

number of edge

mill diameter

shorten overhanging volume of tools

installation precision of tools

run-out precision of spindle and collet

maintenance and replacement of collet

Improve clamping retentivity

improve installation rigidity of work piece

Increase↗

Reduce↘

add more cutting fluid

non-water soluble cutting fluid

Dry.wet change

Increase ↗ more

Decrease ↘ less

Body damage

●Damage of end mill

●
↘

↗
●

●

Damage of
tools point

●Quick wear of
cutting edge

●

●
↘

↗
●

Climb milling

●

↗
●

●Damage (little chipping)

●
↘

Climb milling

●
Dry

●

●Chips on cutting edge

●

●
Wet

↗
●

Machining precision

●Bad surface quality

↗
●

●
↘

●

●
Wet

●

●Wave

●
↘

↗
●

●

●Unlevelling side

●
↘

Conventional
milling

●

↗
●

●

●Burrs and down edges

●
↘

●Produce chattering

●
↘

↗
●

●
↘

↗
●

●

Chip removal

●Unsmooth discharge
of chips

●
↘

●

●
↘

Others

⑴ When the edge is grinded too much, usually problem like end mill will be damaged and
machining surface's precision is not good etc will happen. We suggest sharpening ASAP.

⑵ Shortening the edge length of end mill to the utmost within the allowed range, and improving
machine tools' installation rigidity, precision, are efficient solution to any problem.

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