Milling plays a pivotal role in the manufacturing industry, shaping countless products and components we use daily. Especially when precision is paramount, understanding the nuances between different milling techniques becomes crucial. One such distinction lies between conventional milling (or up milling) and climb milling (or down milling).

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Selecting the right milling technique is crucial for achieving the desired results. The choice between conventional milling (up milling) and climb milling (down milling) depends on various factors, including the material being machined and the specific challenges faced during the machining process.

Fusion 360 chamfertutorial

In this technique, the milling cutter is offset to one side of the workpiece’s symmetrical plane. As the cutter exits the material, the chip thickness is at its minimum. This method is particularly suitable for materials like stainless steel, which have a high deformation coefficient and are prone to work hardening.

Attached are screenshots of a speed handle I made recently. I have modeled the chamfers that I wanted and successfully machined them using the following parameters using the 2D chamfer tool path. This is a 1/4" Diameter, 4 Flute chamfer tool with a .060" flat tip. The chamfer tip offset needs to be greater than the chamfer being cut. Feel free to message me if you need any further help with this.

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The chamfer is in the drawing. Top edge of chamfer is selected, height is model top, bit size is correct 1/4" 90 degree, chamfer width 0, chamfer tip offset 0.1, chamfer clearance 0.

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Here, the milling cutter is also offset to one side of the workpiece’s symmetrical plane. However, as the cutter enters the material, the chip thickness is minimal. This results in a smaller initial impact, consistent cutting force, and a smoother milling process. This technique is especially effective when machining carbon steel and high-strength low-alloy steel.

Fusion 360 chamferEmpty toolpath

Note: It’s essential to understand that the determination of whether an operation is conventional or climb milling is based on the feed direction of the workpiece, not the feed direction of the cutter.

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In the realm of milling operations, the rotation direction of the milling cutter typically remains constant. However, the direction of feed can vary. This has led to the emergence of two prevalent milling techniques: conventional milling (also known as up milling) and climb milling (often referred to as down milling).

Fusion 360 chamferpart of edge

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When the workpiece is positioned centrally to the milling cutter, the process is termed as symmetrical milling. In this method, the chip thickness remains consistent during both the entry and exit of the cut, resulting in a substantial average cutting thickness.

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A paramount consideration during milling is the formation of chips. The position of the milling cutter plays a decisive role in chip formation. It’s essential to ensure that a thick chip forms as the cutter edge enters the material and a thin chip as it exits. This “thick to thin” principle guarantees a stable milling process, ensuring that the chip thickness is as minimal as possible upon the cutter’s exit. This approach not only enhances the quality of the finished product but also prolongs the life of the milling tools.

In conventional milling, the thickness of the chip decreases progressively from the start of the cut until it reaches zero by the end of the cut. This absence of friction prevents the cutting edge from scraping and rubbing against the surface of the part before the actual cut begins. Moreover, because the chips move from thick to thin during conventional milling, it’s less likely to form burrs when machining ductile materials.

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Conventional milling and climb milling are foundational techniques in the milling process. For a distinguished manufacturing service provider, mastering these methods is non-negotiable. At Prototool, we not only understand the intricacies of these techniques but excel in their application. Drawing from our vast experience and expertise, we ensure that every project we undertake is a testament to our commitment to precision and quality. When you choose Prototool, you’re choosing a partner who has made it their mission to master the very basics, ensuring that your designs are brought to life with unparalleled accuracy and finesse.

I believe NYCNC has a great tutorial on this topic. I have no idea if it still valid for this build of fusion 360. They do it modeled and not modeled. I can see benefits to them both.

Conventional milling is when the milling cutter spins in the same direction as the workpiece moves. In simpler terms, the cutter rotates against the direction of the feed.

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Milling operations, whether conventional or climb, come with their unique set of advantages and challenges. Understanding these characteristics can help manufacturers make informed decisions about which method to employ for a specific task.

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I agree. I don’t even put them in the drawing. I have had a similar problem also making threads in large bronze prop nuts.

Fusion 360 chamfermultiple depths

What is the width of the chamfer on your part? I believe the the offset must be greater than the width of the chamfer. I don’t model chamfers in my designs so I’m not sure if this helps. I do all my chamfers in the CAM operations.

I am having a problem with chamfering a part I have cut. The toolpath and simulation looks to be correct, however the bit does not touch the part. I have tried everything I can think of.

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In climb milling, the chip thickness starts from zero and gradually increases as the cutter tooth rotates until the end of the cut. The cutter tooth doesn’t immediately engage with the workpiece; instead, it skids on the already machined surface. This skidding can harden the surface, deteriorating its quality and accelerating the wear of the cutter tooth.

I have had good luck using 2D Contour on the bottom edge if the model has the chamfers, or 2D Chamfer if I didn’t model them.

I’ve not seen any good solutions for modeled chamfers. You’d think it would be the easiest way to tell fusion what you want. I just stopped modeling them based on everything I read and suggestions from others. Way easier to program without them currently, but I’d much prefer to include them in the model.

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On the other hand, in climb milling, the milling cutter spins in the opposite direction to the way the workpiece is moving. This means the cutter rotates in the same direction as the feed.

End face milling, a crucial aspect of the machining process, can be approached in various ways depending on the relative position of the milling cutter to the workpiece. Understanding these techniques and their implications can help in achieving optimal results.