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Milling cutter is one of the indispensable tools for modern metal processing. What are the characteristics of milling cutters? What factors should be considered when choosing a milling cutter?
What are the characteristics of milling cutters?
What materials are used for cutting tools?
How to choose the right milling cutter?
1. Groove/tooth: The groove of the milling cutter is a deep spiral groove extending along the tool, and the sharp blade along the edge of the groove is called a tooth. The teeth cut the material and pull the chips of this material up to the groove by the rotation of the cutter. Each flute almost always has one tooth, but some cutting machines have two teeth per flute.  The terms flute and tooth are often used interchangeably. Milling-tools may have one or more teeth, the most common are 2, 3, and 4. Generally, the more teeth the tool has, the faster it can remove material. Therefore, a four-tooth milling cutter can remove material at twice the speed of a two-tooth milling cutter.
2. Helix angle: The groove of the milling cutter is almost always helical. If the chip flute is straight, the entire tooth will immediately impact the material, causing vibration and reducing accuracy and surface quality. Setting the grooves at a certain angle can make the teeth gradually enter the material, thereby reducing vibration. Generally, finishing knives have a higher rake angle (tighter helix) to provide a better finish.
3. Heart cutting: Some milling tools can directly drill down (cut into) the entire material, while others cannot. This is because the teeth of some tools cannot extend all the way to the center of the end face. However, these knives can be tilted down about 45 degrees.
4. Coating: A suitable tool coating can have a significant impact on the cutting process by increasing the cutting speed and tool life and improving the surface finish. Polycrystalline diamond (PCD) is a very hard coating used for cutting tools and must withstand high abrasive wear. The service life of PCD coated tools may be 100 times that of uncoated tools. However, the coating cannot be used at temperatures higher than 600 degrees Celsius or on ferrous metals. Tools for processing aluminum are sometimes coated with TiAlN. Aluminum is a relatively sticky metal that can weld itself to the teeth of tools, making them appear dull. However, it tends not to stick to TiAlN, allowing the tool to be used in aluminum for a longer time.
5. Tool holder: The tool holder is the cylindrical (non-grooved) part of the tool used to fix and position it in the tool holder. The shank can be perfectly round and can be fixed by friction, or it can have a Weldon Flat (Weldon Flat), in which set screws (also known as flat head screws) make contact to increase torque without slipping the tool. The diameter may be different from the diameter of the cutting part of the tool, so it can be fixed by a standard tool holder. § The length of the shank may also have different sizes, the shank is relatively short (about 1.5 times the diameter) (5 times the length), and super long (8 times the diameter) ) And super long (12 times the diameter)
1. Carbon steel is the cheapest in the bunch. This is why it can still be used. Since carbon steel is not very durable, it is only suitable for low-speed operation. Carbon steel loses its hardness at 200°C. This is the reason for the reduced speed-to keep the heating effect low.
2. High-speed steel is a kind of tool steel. Compared with ordinary carbon steel, some alloy elements are added to provide better heat resistance and wear resistance. Although the life cycle of such tools has increased, the cost has also increased. It loses hardness at 600°C. Therefore, higher milling speeds are suitable for these tool steels.
3. Cemented carbide is harder than high-speed steel, but the toughness quality is not so impressive. A higher hardness provides better protection against wear, but a lower level of toughness makes it easier to crack and chip. The maximum temperature used is 900°C.
4. Cutting ceramics is even harder than cemented carbide, but has a decline in toughness. Both alumina and silicon nitride are used to produce tools with different properties. Ceramic cutting tools tend to crack when used on hard materials and at high temperatures. Therefore, for example, they are not actually suitable for processing steel. Otherwise, the tool life will be short.
1. The size of the cutting tool should be suitable for the surface size of the part to be processed
2. End mills are usually used to machine the outer contours of flat parts
3. Carbide tools can be used for milling
4. High-speed steel end mills can be used to process bumps
5. Spiral milling cutters are ideal for machining rough surfaces or rough machining holes
6. When machining solid contours and variable-angle contours, ball-end milling cutters, ring milling tools, conical milling cutters and disc milling cutters are often used
Modern high-performance milling cutters combine high cutting data and long tool life. Therefore, they help to improve the productivity of the manufacturing process and bring a more favorable cost structure. Therefore, it is very important to choose qualified milling cutters. If you are looking for high-quality milling cutter at a reasonable price, Zhu Xia Metal products Co., Ltd. will provide you with the best products