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Ttm 2019.1 Face Milling

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Ttm 2019.1 Face Milling TTM 2019.1 FACE MILLING Copyright © 2018 Seco Tools AB Copyright © Seco Tools AB SAFETY FIRST Emergency Exit Emergency Number Alarm Assembly Point Protective Equipment Copyright © Seco Tools AB TTM 2019.1 Face milling Seco and face milling Seco has a long and proud history in face milling. Today, we offer a wide range of face milling products to meet the roughing, semi- finishing and finishing needs of our customers. With our modern production techniques and patented technology, combined with our world class insert grades, Seco offers a comprehensive array of cutters to overcome a variety of machining challenges. Copyright © Seco Tools AB 3 What is face milling? . In face milling the surface is perpendicular to the cutter axis. Face milling can be used for roughing, semi finishing and finishing. Roughing operations are completed to create a plainer surface with the highest metal removal possible. Semi-finishing usually requires a nice surface appearance and can be combined with a roughing operation. Finishing operations typically have a small depth of cut combined with tight requirements on surface quality, and parameters are often measured with Ra, Rz and/or waviness specifications. Copyright © Seco Tools AB Cutting forces . Cutting forces need to be considered when selecting the best face mill for an operation. The lead angle of the face mill changes the force direction applied in the machining process. Cutting forces are directed bi-axially, meaning forces are directed both axially and radially almost equally. Copyright © Seco Tools AB 5 Cutting forces in the face milling process . 43° to 48° lead angel . the most common variant used . Unstable machining operations and/or long overhangs . 71°-75° lead angle . higher depths of cut with the same size I.C.< on the insert . beneficial at clamping fixture or other obstacle that cannot be avoided in the machining process. 88°-89° lead angle . high depth of cut capabilities with smaller I.C. inserts. optimal when machining next to a side wall on a workpiece . to avoid fixture clamping and other obstacles in the machining process. produces very high radial cutting forces (needs to be kept in mind in relation to fixture and machine stability) Copyright © Seco Tools AB 6 Axial and radial angles . The cutting geometry has a big impact on tool performance . The combination of axial and radial rake angles and the lead angles influences how the cutter will perform. The primary angles that should be noted are . Lead angle (KAPR) . Axial rake angle (GAMP) . Radial rake angle (GAMF) . Altering these angles results in many potential combinations, each providing different behaviors and features. Copyright © Seco Tools AB 7 Axial and radial angles Positive axial rake (GAMP) and positive radial rake (GAMF) face mill . Example: Octomill™ . Benefits • Smooth cutting action that produces low cutting forces • Very good chip evacuation, ideal in sticky materials • Good surface smoothness, less risk of vibrations • Reduced risk of chip jamming, reduced risk of marking of the workpiece . Disadvantages • Reduced cutting edge strength • Unfavorable entry contact • Tendency to pull the workpiece upwards away from the machine table or fixture clamping Copyright © Seco Tools AB 8 Axial and radial angles Positive axial rake (GAMP) and positive radial rake (GAMF) face mills . Example: Octomill™ . When to apply on the machine . Lower powered spindles . At stable setup . In sticky materials like stainless steels and titanium . Weak spindles with a lot of “play” . Note: Weak spindles with a lot of “play” or very weak fixturing can be problematic with this type of system because of the tendency to pull the workpiece up and away from the machine table. Copyright © Seco Tools AB 9 Axial and radial angles Negative axial (GAMP) and negative radial (GAMF) . Example: Double Octomill™, R220.88 with SNMU inserts and Double Quattromill™ . Benefits . A strong cutting edge geometry . High productivity with the ability to take heavy feed rates and endure interrupted cuts and other difficult machining operations . Tendency to push the workpiece toward the machine table or fixture, which can be an advantage in some cases and a negative in others . Disadvantages (potential) . Higher cutting forces . Chip jamming . Obstructions Copyright © Seco Tools AB cont… 10 Axial and radial angles Negative axial (GAMP) and negative radial (GAMF) . Example: Double Octomill™, R220.88 with SNMU inserts and Double Quattromill™ . When to apply on the machine . Ideal for steels and cast irons . Can also be effective in stainless steels and super alloys if the insert is provided with the proper cutting edge and high positive rake angles. Good choices for heavy duty, strong spindles and on rigid setups. When using high positive geometries, such as ME12 and M12 for Double Octomill, this cutter can be applied on less rigid and strong spindles (will require some consideration to make the cutters work properly and effectively) Copyright © Seco Tools AB 11 Axial and radial angles Positive axial (GAMP) and negative radial (GAMF). Example: Quattromill™ . Benefits: . Good chip removal from the cutting zone . Suitable for machining sticky materials . Favorable cutting forces with very little axial push or pull, optimal for unstable machining operations . Disadvantages (potential) . Typically single sided inserts with less number of edges per insert. Copyright © Seco Tools AB 12 Axial and radial angles Positive axial (GAMP) and negative radial (GAMF) . Example: Quattromill™ . When to apply on the machine . The operation zone for this type of geometry is wide because it combines the advantages of both positive axial cutting rakes and negative radial rakes, which make for an easy cutting system with strong edge protection. Copyright © Seco Tools AB 13 Differential pitch . Differential pitch - the variation of angles between pocket seats from one to the next. Helps to reduce vibrations in the machining process . Increases tool life and surface finish possibilities. Most standard pitch cutters are differentially pitched. Keep in mind that close pitch Normal versions typically do not have differential pitch pitch. Differential pitch Copyright © Seco Tools AB 14 Fixed pocket and cassette cutter styles Different types of cutters . Fixed pocketed cutters . Inserts are mounted and fixed in the cutter body with insert screws or wedges. The most rigid types since they are contained in the solid cutter body. Default selection when adjustability is not needed to compensate for runout. Cassette cutters . Offer the versatility of adjustment to eliminate or reduce axial runout. Offer the ability to replace one pocket by replacing a cassette instead of entire cutter body. Disadvantages: . More spare parts . In some cases a less rigid cutter . Offer limited number of teeth Copyright © Seco Tools AB 15 Insert clamping Common types of insert clamping . Mounted inserts with a center locking screw . Provides a secure way of mounting inserts to the body. Limitation of center-locking types is that spacing must allow a torque wrench within the socket . Wedge-style type . Screw and wedge combine to lock the insert in the pocket. The key advantage of wedge-style mounting is the ability to make super close pitch cutters. Copyright © Seco Tools AB 16 Factors in surface finish Fixed pockets vs cassette versions Axial run-out with a non . Surface finish is greatly influenced by the adjusted cutter axial runout of the cutter. Seco standards for most face milling systems are 20 microns of axial runout on fixed pocket cutters. Cassettes give a better . Combined with insert tolerances, this means surface finish when approximately 30–40 microns from insert to correctly adjusted insert. Affects the ability to obtain high surface finishes . The cassette version gives the ability to set the cutter to eliminate or reduce axial runout from one insert to the next. Copyright © Seco Tools AB 17 Factors in surface finish Insert geometries . Smaller corner radii can produce very pronounced machining marks on the workpiece. Larger corner radii produce a wider mark Small radius and can create a better appearance. corner insert . Note that the surface peaks and valleys can also be affected. For example comparing a 45° lead and small corner radii to the same Large radius insert with a larger radii, the bigger radii will corner insert produce a better finish Copyright © Seco Tools AB 18 Factors in surface finish Insert geometries . Chamfers or faceted inserts will produce a wider machining mark. Wiper inserts produce a very high surface finish. Faceted corner insert . Wipers have a geometry with a very large radii on the contact face of the insert to rub/wipe the material smooth. Wipers reduce machining marks and also Faceted insert plus wiper insert improve surface roughness measurements. Copyright © Seco Tools AB 19 Factors in surface finish . Consider machine and fixture rigidity during the selection of a cutter and inserts. Wipers create a lot of axial cutting forces and this can be problematic if the machine or fixture is weak. Insert geometry . The size of radii and integrated wiper will influence what level of surface finish can be achieved. In sticky materials, the cutting edge geometry also plays a role in the surface finish. cont… Copyright © Seco Tools AB 20 Factors in surface finish . Speeds and feeds are critical to optimizing surface finish. When using a wiper geometry think of calculating the feed per revolution in relation to the effective wiper flat per revolution. Create a better surface finish by increasing surface speed keeping same feed rate = lower feed per revolution. This can also be a problem solver in some sticky materials, as it can help reduce bonding of the material to the insert which can drag back across the workpiece and create poor finish. Copyright © Seco Tools AB 21 Average chip thickness Three primary factors affect average chip thickness: . ae (radial tool engagement) . lead angle of the insert (KAPR) . feed per tooth (fz). Feed rate Average chip thickness can affect both tool life and cutting.
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