Carbide End Mills are expensive tools, so it's important to extend their life. We'll discuss 10 Main ways you are burning your Tools Faster
Introduction
You may not realize it, but there are several things you're doing to kill your end mills prematurely. Carbide end mills are expensive tools, so it's important to do everything possible to extend their life. In this article, we'll discuss the 10 Main ways people kill their end mills, as well as some tips on how to avoid these mistakes. By following these simple guidelines, you can keep your end mills sharp and in good condition for a long time.
1. Never let your end mills run dry
This will cause the bits to break and chip, leading to rapid dulling and decreased performance. Always make sure that you have plenty of coolant on hand when you're using your mills especially milling Aluminium & its Alloys, Steel, Stainless Steel, Super Alloys. Use Right Coolant & Right Coolant Mix IMPORTANT TIP >> i.e. at least 6% and about 10~12% for Super Alloys. Coolants are designed to minimize friction and heat build-up by forming a thin layer on the tools’ cutting surfaces. But too much coolant %age then advised restricts chip formation on the cutting edge, which creates extra heat in the cut zone. This means that not only do you increase friction, but it also puts wear and tear on your cutting tools faster than necessary.
2. Avoid excessive heat
This can cause the cutting edges to wear quickly and then increase the Spindle Load and finally the End Mills will break off leading to an overall decrease in the life expectancy of your carbide end mills hence increasing your Tooling Cost Per Component and resulting in Losses at the shop floor.
3. Optimize your cutting speed and feed rate
Always optimize your Cutting Speed & feed Rate for the specific material to machine since running Carbide End Mills Too Slow or Too Fast both result in Poor Performance or Premature Failure of Carbide End Mills , hence always follow the Manufacturers Speed & Feed Guidelines to start with Or you can take help of ROHIT's Technical Team for help.
Important Tip: Always follow manufacturers Feed & Speed Chart
4. Increase your DOC and reduce your WOC / RDOC
Most of the machinist till today likes to Feed there end mills with Bigger WOC or Width of cut or Radial cuts instead they should follow High Efficiency Milling which is more prevalent in advanced CNC shops.
IMPORTANT TIP: Always run with longer DOC (Depth Of Cut) and lesser WOC / RDOC (Width of cut or Redial Depth of Cut) as this leads to consistent heating all across the periphery of the Carbide End Mills especially in Side Milling applications hence resulting in consistent wear of the end mills hence increased tool life , lower Cost per component & to top it with Higher Productivity.
5. Wrong Tool Geometry
Every machinist wants to have that ONE END MILL To work for ALL Types of Applications and Materials; however Use the right tool for the job meaning use Material specific end mills i.e. a Die Steel Specific end mills which is meant to work on 60hrc will not work on Aluminum materials even though Aluminum is softer material. Rohit makes Material specific Carbide End Mills like
6. Never Use Too Long Flute Lengths To Get More Regrinds
Always use the required flute length tools instead of long flute lengths to get more regrinds as the result of EXTRA LONG FLUTE LENGTHS is that you snap your tools or have to run your tools at slower feeds due to overhang or less rigidity hence resulting in Loss of Invaluable Machine time on the shop floor.
7. Use Recessed or Deep Reach End Mills instead of Long Flute Lengths for Cavities
Recessed or Deep Reach end mills are a great option for deep cavity machining so always use the same for more rigidity as the longer flute lengths will result in breakage and not straight walls in deep cavity applications.
8. Use Right Coating on your End Mills
All manufacturers provide multiple coatings and each coating pertains to a particular type of material machining so contact your manufacturer for right tool for the job. Rohit Cutting Tools offer varied types of PVD coating to choose from i.e. AlTiN (Aluminum titanium nitride coating), TiAlN (titanium aluminum nitride), TiN (Titanium Nitride) , AL-Pro, NOVA, PEROX etc.
9. Use Variable Helix Carbide End Mills for best performance
Variable Helix End Mills give best results by providing Chatter-Free Machining and hence resulting in great finish and long Tool Life. Variable helix end mills like 330 Series and 333 Series are great options to have in your tool box to work on Varied type of materials like Alloy Steel, Stainless Steel, Titanium, Inconel etc.
10. Too Much Spindle Run Out on your Machine
Research says for every 10microns increase in spindle run out you loose about 20% of your Tools life and performance so it is imperative to take good care of your machine and its spindle which is the lifeline for the machinist.
Conclusion
So, if you want to keep your carbide end mills and other carbide tools in good condition for as long as possible AND avoid doing any of the things mentioned above then you are rest assured to make Profits at shop floor and complete the most difficult of projects.
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