Measures to eliminate machining faults of end mill

Fault
Occurrence situation
Measures
Tools breaking (when
using solid small
-diameter and brazing
small-diameter
end mill)
¡ñWhen the tools cuts in a work piece

¡ñWhen the tools is pulled out
¡ñReduce feed

¡ñReduce overhanging volume

¡ñShorten the cutting edge length to the minimum limit of necessary length
¡ñWhen the tool is
machining normally
¡ñReduce feed

¡ñWear control ¡ú replace tools as early as possible

¡ñReplace fixture or spring collet

¡ñReduce overhanging volume of the tools

¡ñ Make passivation treatment to the tools

¡ñIf using 4-flute end mill, change it to 3-flute or double-flute mill
(prevent chip jamming)

¡ñChange dry milling to wet milling (using cutting fluid). When wet milling supplies the fluid from front,
change it to be supplying from back or cross upper side. The flow of cooling fluid shall be sufficient
¡ñWhen feed direction changes
¡ñUse arc interpolation (NC machine tool), or halt

¡ñReduce the feed before and after direction change

¡ñReplace fixture or spring collet
Chipping
¡ñChipping at tools point
¡ñUse manual regrinding to chamfer at corner part

¡ñChange climb milling to conventional milling
¡ñDamage in cutting depth interface
¡ñ Change climb milling to conventional milling

¡ñReduce milling speed
¡ñChipping is distributed in
central part or in the whole
cutting edge
¡ñMake passivation chamfering or enlarge chamfering

¡ñChange rotation of spindle (when the machine tool is vibrating)

¡ñIncrease milling speed

¡ñWhen there is friction sound during milling, increase feed

¡ñIf applying dry milling, change it to wet milling or use air to cool

¡ñ Replace fixture or spring collet

¡ñReduce cutting speed
¡ñLarge chipping of cutting edge
¡ñReduce feed

¡ñIf using 4-flute end mill, change it to 3-flute or double-flute end mill

¡ñMake passivation chamfering or enlarge chamfering

¡ñReplace fixture or spring collet

[when using solid end mill]

¡ñReduce milling speed

¡ñIf applying dry milling, change it to wet milling. When wet milling supplies the
fluid from front, change it to be supplying from cross upper side or back. The flow
of cooling fluid shall be sufficient.[when using brazing end mill]

¡ñIf applying wet milling, change it to dry milling, using compressed air. When air is supplied
from front, change it to be supplying from back or cross upper side. Its flow shall be sufficient

¡ñIn steel's slot milling, with standard cutting condition as target value, select appropriate milling
speed (at low milling speed¡­¡­It will produce low speed damage, and pressing object will split
and be damaged.) (at high milling speed ¡­¡­Chips will jammed and it will produce thermal
cracking while milling deep slot
Early wear of tools
¡ñReduce milling speed

¡ñIf it is conventional milling, change it to climb milling

¡ñIncrease feed

¡ñAdopting wet or compressed air cooling milling

¡ñIf using regrinding end mill, improve roughness of back