High efficiency millingpdf

When you work with high-efficiency milling cutters, the wear dissipates heat in all directions. However, in the case of ordinary milling cutters, the heat concentrates in the lower portion of the tool.

How did this happen? What are high-efficiency milling cutters? What is so different about them? Read on as I answer all these questions.

High efficiency millingtools

Axial Depth of Cut or ADOC is the distance milling cutters engage a workpiece along their axis or centerline. High-efficiency milling cutters have a higher axial depth of cut, while ordinary milling cutters have a lower axial depth of cut.

Material Removal Rate or MRR is the measure of cubic inches of material removed during the milling application in one minute. You can calculate it by multiplying three factors with each other: Axial Depth of Cut (ADOC), Radial Depth of Cut (RDOC), your feed per minute (feed rate).

The differences in axial depth of cut, radial depth of cut, and the direction of passes bring about the differences in heat dissipation while cutting the workpiece.

High efficiency millingprocess pdf

One of our European customers, a machinist, used to produce aerospace machine parts using ordinary milling cutters. But after shifting to high-efficiency milling cutters, his processing capacity increased by 1.5 times in one day.

High Efficiency MillingCalculator

High-efficiency milling cutters have a higher MMR with an increased feed rate, while ordinary milling cutters are worked at a relatively lower MMR with a conservative feed rate.

Trochoidalmilling

As there are more radial passes, the heat energy spreads over the entire cutting edge, instead of concentrating in the lower portion of the endmills. It decreases the chances of tool failure and makes your processing more efficient.

Flutes are the sharp grooves that corkscrew upwards along the length of milling cutters. Their job is to cut the workpiece by spinning at high speeds. High-efficiency milling cutters have a higher number of flutes, adding to the rigidity of the tool. In the case of ordinary milling cutters, there is decreased rigidity due to a lesser number of flutes.

Radial Depth of Cut or RDOC is the depth of milling cutters along their radius in the workpiece as they make a cut. High-efficiency milling cutters have a lower radial depth of cut, while ordinary milling cutters have a higher radial depth of cut.

High-efficiency milling cutters take more radial passes on their workpiece, using the entire flute to make a smaller yet deep cut. Ordinary milling cutters, on the other hand, take more axial passes. They start at the top and work their way down into the workpiece, taking a huge cut at the bottom.

High efficiency millingmachine

Although both high-efficiency milling cutters and ordinary milling cutters are used for milling, there lies a significant difference between them.

High-efficiency milling cutters have a large core diameter, adding to the strength of the milling cutter. Conversely, ordinary milling cutters generally have a small core diameter.

High-efficiency milling cutters differ from ordinary milling cutters in terms of how they’re built and how they’re used during processing. Let’s review their differences under seven categories.

High-efficiency milling cutters such as solid carbide endmills have a greater number of flutes with a strong and heavy core. They serve as tools for high-efficiency milling processes. In this toughing technique, these high-efficiency milling cutters run at higher speeds with a lower RDOC (Radial Depth of Cut) and a higher ADOC (Axial Depth of Cut).