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Helical's Machining Guidebook Helical MACHINING GUIDEBOOK Quick Reference eBook for CNC Milling Practices & Techniques 1 | Machining Guidebook | © 2016 Helical Solutions, LLC Helical Contents Milling Techniques & Strategies Terminology & Common Calculations 01 | Milling Techniques . 3 04 | End Mill Construction . 37 Types of Tool Entry . 4 Geometry Definitions . 38 Ramping . 6 End Mill Construction . 40 Thin Wall Milling . 8 End Mill Anatomy . 42 Deep Pocket Milling . 10 05 | Common Calculations . 51 Finishing . 11 Decimal Conversion Chart . 52 Ball Nose Strategy . 13 Common Milling Calculations . 53 Corner Engagement . 17 Speeds & Feeds . 54 Angle Engagement . 19 Conventional vs Climb Milling . 20 06 | Tool Holding . 55 Chip Thinning . 22 Tool Holding . 56 Preventing Tool Pull Out . 58 02 | High Efficiency Milling . 23 High Efficiency Milling . 24 HEM Tooling . 25 Troubleshooting 03 | Depth of Cut . 26 07 | Troubleshooting . 60 Depth of Cut . 27 Troubleshooting Chart . 61 Depth of Cut - Peripheral . 28 Tool Wear . 65 Depth of Cut - Slotting . 34 Tool Deflection . 69 Copyright © 2016 by Helical Solutions, LLC . All rights reserved . This book or any portion thereof may not be reproduced or used in any manner whatsoever without the express written permission of Helical Solutions . 2 | Machining Guidebook | © 2016 Helical Solutions, LLC Helical 01 Milling Techniques Types of Tool Entry . 4 Ball Nose Strategy . 13 Ramping . 6 Corner Engagement . 17 Thin Wall Milling . 8 Angle Engagement . 19 Deep Pocket Milling . 10 Conventional vs Climb Milling . 20 Finishing . 11 Chip Thinning . 22 3 | Machining Guidebook | © 2016 Helical Solutions, LLC Helical Types of Tool Entry The type of part entry that is programmed has a lot of influence on the tool’s success and is one of the most punishing Theoperations type of part for entry a cutter programmed . Below is we very have influential listed in thesome tool’s common success and part one entry of the methods most and suggestions on how to perform them punishingsuccessfully operations . for a cutter. Below we have listed some common part entry methods and suggestions on making these most successful. The type of part entry programmed is very influential in the tool’s success and one of the most punishing operations for a cutter. Below we have listed some common part entry methods and suggestions on makingPre-Drilled Pre-Drilledthese most successful. Hole Hole The type of part entry programmedPre-drillingPre-drilling a hole is a very hole to fullinfluential to pocket full pocketin depth the tool’s (and depth success5-10% (and larger and 5-10% onethan of the larger the end most millthan the end mill diameter) is the safest practice diameter) is the safest practice of dropping your end mill into a pocket. This punishing operations forPre-Drilledof a cutter.dropping Below Hole your we have end listed mill intosome a commonpocket part. This entry method methods ensures and the least amount of end work abuse and method ensures the least amount of end work abuse and premature tool suggestions on making these most successful. wear.Pre-drillingpremature a hole tool to wearfull pocket . depth (and 5-10% larger than the end mill diameter) is the safest practice of dropping your end mill into a pocket. This methodPre-Drilled ensures Hole the least amount of end work abuse and premature tool wear.Helical Interpolation Pre-drilling a hole to full pocket depth (and 5-10% larger than the end mill A very common and safe practice with ferrous materials. Employing corner diameter) is the safest practice of dropping your end mill into a pocket. This radius end mills during this operation will increase tool wear and lessen methodHelical ensures Interpolation the least amount of end work abuse and premature tool corner breakdown. We recommend a programmed helix diameter >110-120% wear.Helical Interpolation ofA verytool diameter.common and safe practice with ferrous materials. Employing corner radiusA very end common mills during and this operationsafe practice will increase with ferrous tool wear materials and lessen . Employing corner radius end mills during this Our new speed & feed app “Milling Advisor” will give you specific cutting cornerHelicaloperation breakdown. Interpolation will decrease We recommend tool wear a programmed and lessen helix corner diameter breakdown >110-120% . We recommend a programmed helix parametersof tool diameter. for operations like this (see pg. 47). A diametervery common >110-120% and safe practice of tool withdiameter ferrous . materials. Employing corner Our new speed & feed app “Milling Advisor” will give you specific cutting radiusRamping-In end mills during this operation will increase tool wear and lessen cornerparameters breakdown. for operations We recommend like this (see a programmed pg. 47). helix diameter >110-120% Download the Helical Milling Advisor™ at www.helicaltool.com to get ofThis tool type diameter. of operation can be very successful, but institutes many different torsional forces the cutter must withstand. Finding a tool with good core strength Ramping-In real-time Helical Interpolation information for your specific application. Ourplus newroom speed for proper & feed chip app evacuation “Milling Advisor” is key. willEmploying give you corner specific radius cutting end mills parametersduringThis type this of operation operationfor operations will can help belike immensely.very this (seesuccessful, pg. 47). but institutes many different torsional forces the cutter must withstand. Finding a tool with good core strength BelowplusRamping-In room are somefor proper suggested chip evacuation starting ramp is key. angles: Employing corner radius end mills •during Non-Ferrous this operation Materials: will help 3ºimmensely. – 10º This• Ramping-InFerrous type ofMaterials: operation can be1º very – 3º successful, but institutes many different torsionalBelow are forces some the suggested cutter must starting withstand. ramp angles:Finding a tool with good core strength plusOur• ThisNon-Ferrous newroom type speed for of proper Materials: &operation feed chip app evacuation “Milling can3º – 10ºbe Advisor” isvery key. successful, willEmploying give you corner specific but radiusinstitutes cutting end millsmany different torsional forces the cutter must duringparameters• withstandFerrous this Materials: operation for . Finding operations will ahelp tool like 1ºimmensely. this –with 3º (see good pg. 47). core strength plus room for proper chip evacuation is key . Employing corner radius end mills during this operation will help immensely . Below OurStraight new are speed some Plunge & suggested feed app “Millingstarting Advisor” ramp angles: will give you specific cutting •parameters Non-Ferrous for Materials: operations like3º this – 10º (see pg. 47). •The BelowFerrous least Materials:arepreferred some method suggested and1º – one3º starting that can rampeasily break angles: a tool. The tool must beStraight center cutting. Plunge End milling incorporates a flat entry point making chip Ourevacuation new speed tough, & feed tool pressureapp “Milling very Advisor” high and will success give you random specific at cutting best. parametersThe •least Soft/Non-Ferrous preferred for operations method like and Materials: this one (see that pg. can3º 47). – easily 10º break a tool. The tool• Hard/Ferrous must Materials: 1º – 3º Please note: Drill bits are intended for straight plunging and we highly recommend this typebe center of tool cutting.for this operation. End milling incorporates a flat entry point making chip evacuationStraight tough,Plunge tool pressure very high and success random at best. 4 | Machining GuidebookOur new | © speed2016 Helical & feed Solutions, app “Milling LLC Advisor” will give you specific cutting Helical ThePlease least note: preferred Drill bits aremethod intended and for one straight that plungingcan easily and break we highly a tool. recommend The tool must this parameterstype of tool for for this operations operation. like this (see pg. 47). be center cutting. End milling incorporates a flat entry point making chip evacuationOur new speed tough, & feedtool pressure app “Milling very Advisor” high and will success give you random specific at cutting best. Side Entry (use tools with a corner radius for best results) Pleaseparameters note: Drill for bitsoperations are intended like thisfor straight (see pg. plunging 47). and we highly recommend this type of tool for this operation. Straight Entry Roll-In Entry OurSide new Entry speed &(use feed tools app with “Milling a corner Advisor” radius forwill best give results) you specific cutting Straightparameters entry into for the operations part like this (see pg. 47). Rolling into the cut ensures takesStraight a toll onEntry the cutter. Until the Roll-Ina cutter to Entry work its way to full cutter is fully engaged, the feed enagagement and naturally Side Entry (use tools with a corner radius for best results) rateStraight upon entry entry into must the bepart reduced acquireRolling into proper the cutchip ensures thickness. bytakes at least a toll 50%.on the cutter. Until the Thea cutter feed to rate work in thisits way scenario to full Straightcutter is fully Entry engaged, the feed Roll-Inshouldenagagement be Entry reduced and naturallyby 50%. rate upon entry must be reduced acquire proper chip thickness. Straight entry into the part Rolling into the cut ensures by at least 50%. The feed rate in this scenario takes a toll on the cutter. Until the a cutter to work its way to full should be reduced by 50%. cutter is fully
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