Technical Helps TECHNICAL
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Technical Helps TECHNICAL CONTENTS Troubleshooting Guide - End Mills 230 Troubleshooting Guide - Drills 231 Troubleshooting Guide - Reamers 232 Tool Coating Types 233 Carbon Fiber Options 234 Formulas 235 SFM/RPM Conversion Charts 236 General Milling Guide - fractional 237 High Performance Milling Guide - fractional 238 General Milling Guide - metric 239 High Performance Milling Guide - metric 240 Alumastar Coated Milling Application Guide 241 VRX/VHM Milling Application Guide 242 V4 High Speed Milling Guide - fractional 243 V4 High Speed Milling Guide - metric 244 V5 High Speed Milling Guide - fractional 245 V5 High Speed Milling Guide - metric 246 High Rc Finisher Milling Guide - fractional 247 High Rc Finisher Milling Guide - metric 248 Die Mold Cutter Milling Guide - fractional 249 Die Mold Cutter Milling Guide - metric 250 Diamond Coated Milling Guide 251 Reaming Guide 252 Drill Mills, Chamfering - fractional 253 Drill Mills, Chamfering - metric 254 Drill Mills, Through Hole - fractional 255 Drill Mills, Through Hole - metric 256 Drill Mills, Solids - fractional 257 Drill Mills, Solids - metric 258 Drilling Guide - fractional 259 Drilling Guide - metric 261 High Performance Mini Drills Guide - fractional 263 High Performance Mini Drills Guide - metric 264 High Performance Drilling Guide - fractional 265 High Performance Drilling Guide - metric 266 3-Flute for Aluminum Drilling Guide 267 +1 989-463-6171 fax +1 989-463-3609 229 Troubleshooting for End Mills PROBLEM SUGGESTIONS TECHNICAL Check part rigidity Verify speeds and feeds Chipping Confirm concentricity of end mill in holder Decrease ramp angle or slow down approach Check coolant flow and location Decrease feed rate Decrease axial depth Breakage Use shorter tool or stub holder Resharpen earlier Too light of a cut Leave more stock for finish pass Chattering Decrease axial depth Adjust speeds and feeds Confirm concentricity of end mill in holder Decrease feed rate Part finish Use different style of end mill Check coolant flow and location Check part rigidity Change end mill sooner / too much wear Verify speeds and feeds Burr Increase spindle speed Decrease feed rate Use different style of end mill Check part rigidity Verify speeds and feeds Excessive noise Too light of a cut Confirm concentricity of end mill in holder Work material harder than expected Verify speeds and feeds Tool life Recutting chips Too light of a cut Use different style of end mill Speed too fast Too light of a feed Wear Confirm concentricity of end mill in holder Verify speeds and feeds Verify speeds and feeds Chip welding Check coolant flow and location Use different style of end mill Check coolant flow and location Decrease axial depth Chip packing Adjust speeds and feeds Use different style of end mill Decrease feed rate Decrease axial depth Wall not straight Use shorter tool or stub holder Use different style of end mill ® 230 www.garrtool.com † Metric equivalents are for reference only Troubleshooting for Drills TECHNICAL PROBLEM SUGGESTIONS Reduce feed rate Check part rigidity Constant feed rate Chipping on point Verify speeds and feeds Minimum drill overhang Reduce number of peck cycles Reduce feed rate Confirm concentricity of drill in holder Chipping on O.D. Check coolant flow and location Check part rigidity Reduce feed rate Check your program - is 'R' clearing the part Breakage Check coolant flow and location Check part rigiditiy Increase feed rate Check coolant flow and location Heavy wear on corners Confirm concentricity of drill in holder Check part rigidity Increase feed rate Increase hone relief Long, stringy chips Constant feed rate Increase number of peck cycles Check drill Excessive noise Check part rigidity Check for proper speeds and feeds Lower speeds and feeds Check coolant flow and location Tool life Confirm concentricity of drill in holder Confirm coolant concentration Increase feed rate Hole too small Confirm coolant concentration Confirm drill diameter Reduce feed rate Slow feed rate to start hole Hole too large Increase RPMs Spot hole Increase RPMs by 20% Chip welding Confirm coolant concentration Check coolant flow and location Add a peck cycle to clear chips Increase RPMs Chip packing Reduce feed rate Check coolant flow and location +1 989-463-6171 fax +1 989-463-3609 231 Troubleshooting for Reamers PROBLEM SUGGESTIONS TECHNICAL Check part rigidity Verify speeds and feeds Hole diameter too large Confirm concentricity of reamer in holder Confirm diameter of reamer Check coolant flow and location Leave more stock before reaming Reamer worn Hole diameter too small Check coolant flow and concentration Resharpen earlier Hole was not drilled properly Leave more stock before reaming Hole not straight Confirm concentricity of reamer in holder Check part rigidity Reamer worn Verify speeds and feeds Part finish Confirm concentricity of reamer in holder Check coolant flow and location Check part rigidity Work material harder than expected Verify speeds and feeds Tool life Not evacuating chips properly Too light of a cut Speed too fast Too light of a feed Wear Confirm concentricity of reamer in holder Check coolant flow, location, and concentration Verify speeds and feeds Not evacuating Check coolant flow, location, and concentration Reamer worn Access an assortment of ‘fill-in-the-blank’ prints from our website to aid in the quoting of specials www.garrtool.com ® 232 www.garrtool.com Tool Coatings TECHNICAL General purpose coating - low heat resistance. Good lubricity. TiN (Titanium Nitride) Good abrasion resistance. Recommended for aluminum, brass and bronze applications. Low heat resistance - good lubricity. TiCN (Titanium Carbonitride) Multi-layer coating with good thermal stability for increased speeds and feeds. For semi-dry to dry cutting of most steels, high-nickel alloys, stainless steel and cast iron. Excellent heat TiALN - Balinit® FUTURA resistance, good lubricity. For materials that are 40Rc and under. (Titanium Aluminum Nitride) A single-layer coating whose hardness, oxidation resistance and thermal stability were optimized for material hardness above 52 HRC and high-speed machining of materials that are difficult to work (titanium alloys, Inconel). Competes with ALTiN. Balinit® X.CEED A thin film coating with a low affinity for aluminum, ideal for machining aluminum alloys. The resistance to adhesion of aluminum allows higher speeds or feeds. Coating thickness is intentionally kept lower in order to maintain a sharp edge. ALUMASTAR® (Titanium Diboride - TiB2) Improved productivity in composites and non-ferrous metals. Excellent choice for cutting graphite, fiberglass, and silicon-based aluminum. Can be added to a special for milling or drilling CRYSTALLINE DIAMOND applications. (CVD) Aluminum Chromium-based coatings have excellent wear resistance, thermal shock stability, and hot hardness. Well suited for Titanium, Inconel, and carbon fiber. Balinit® AlCrN-based Multi-layer coating with thermal stability and lubricating properties needed for the drilling of steels, high-nickel alloys, stainless steel, cast iron, aluminum, brass, and bronze. Excellent Balinit® HARDLUBE heat resistance, great lubricity. G6 Generation coating. Greater abrasion resistance, extra shear strength, lower adhesion tendency, maximum toughness and a very smooth surface achieve a quantum leap in drilling ® performance. This coating is particularly advantageous for Balinit HELICA carbide drills. Helica is part of the AlCrN-based coatings. +1 989-463-6171 fax +1 989-463-3609 233 Carbon Fiber Options TECHNICAL Solid micrograin carbide tested for milling of carbon fiber and glass-filled composites Solid micrograin carbide tested for drilling of carbon fiber and glass-filled composites There are many challenges to machining composite materials. Keeping the material from delaminating is key. Our tools Having a quality dust collection system helps prolong tool life and quality of parts have higher rake angles and combinations of left hand and/or right hand spirals to help eliminate 'fraying' of the laminate. 'Clamping' of part to table can cause stress fractures in material Please specify what type of end cut your job requires (i.e. - no end cut, burr type, end mill type, or drill point) These are non-stock specials - uncoated tools built to order in two weeks Having a quality dust collection system helps prolong tool life and quality of parts 'Clamping' of part to table can cause stress fractures in material Please specify what coating, if any, your job requires: - Polycrystalline Diamond (increases tool life up to 20x of an uncoated carbide mill) SERIES 740 - DAGGER - Amorphous Diamond / DLC (increases tool life up to 10x of an uncoated carbide mill) For enlarging existing holes in skin panels, but can drill from solid - Alcrona Coated (increases tool life up to 5x of an uncoated carbide mill) For near reamer finishes in carbon and glass fiber materials - TiCN Coated (increases tool life up to 3x of an uncoated carbide mill) Coatings of choice for this series are polycrystalline diamond and amorphous diamond These are non-stock specials - uncoated tools built to order in two weeks SERIES 780 - 8-FACET POINT (NON-COOLANT FED) SERIES 700 - FIBERGLASS ROUTER Double angle drill point geometry reduces cutting forces to For cutting glass-filled epoxies End cut examples eliminate exit burrs Works well in carbon fiber especially when the honeycomb core is either titanium or aluminum Works in glass-filled epoxy, harder plastics, softer steels, Burr Drill CFRP (Carbon Fiber Reinforced Plastic), and