Some great runs of thumb on end mill selection from NextGen Tooling Navigating the vast array of end mills available in the market can be a daunting task, especially when precision is paramount. To aid in this process, we've outlined a step-by-step guide that addresses crucial considerations for selecting the optimal end mill for your machining needs.
Step 1 – Material Identification: Identify the exact material, its condition (billet, forging, etc.), and hardness (HRC). This information directs you to the Non-Ferrous or Ferrous section of our catalog. Step 2 – Operation Type: Determine whether you'll be roughing, finishing, or both. This guides the choice of the number of flutes and the need for chip breakers. Step 3 – Programming Style: Choose between traditional programming, high efficiency programming (HEM), or a combination. This decision influences the number of flutes (Step 8). Step 4 – ADOC (Axial Depth of Cut): Determine the maximum axial depth of cut the tool will experience in the part. This information helps decide the length of cut (LOC) to deploy. Step 5 – Reach Consideration: Evaluate obstacles to clear and depths to reach. If necessary, consider a reduced necked tool to maintain length of cut while reaching deeper positions. Step 6 – Tool Diameter Selection: Consider the machine taper, cut depth, reach, and part geometry. Keeping the tool diameter under 3/4" for 40-taper machines and adapting the diameter to programming style, cut depth, and reach requirements. Keep in mind what programming style (Step 3) you’re using as HEM can employ smaller diameters than you may be used to. Decide on your cut depth (Step 4). For traditional programming keep it <2xDia., for HEM keep it below 4xDia. Decide on your total reach depth (Step 5). If needing to machine 4xDia. look at a necked tool to maintain strength and minimize deflection. Step 7 – Corner Radius: Determine if your part requires a corner radius. Running a corner radius on an end mill can extend its life and is especially beneficial for pre-finishing. Step 8 – Flute Count: Consider the material and programming type to determine the ideal flute count. Non-Ferrous machining typically requires 2-3 flutes for traditional programming and 3-5 for HEM, while Ferrous machining may need 4-5 for traditional programming and 5-7 for HEM. Step 9 – Tool Holder Selection: Always opt for the most rigid and accurate tool holder with minimal runout. Keep the Total Indicator Runout (TIR) below 0.0005 at the tip of the tool for optimum tool life and success. Consider the use of a side lock holder for specific applications. Remember, our team at Next Gen Tooling is always available to assist you in selecting the correct product. By following these guidelines, you'll navigate the selection process with confidence, ensuring precision and efficiency in your machining operations.
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compiled & edited by Bernard Martin Carbide and HSS circular saws are essential tools in the metalcutting industry, however, breakage issues arise that impact performance and efficiency. In this article, we'll look into the common causes of carbide circular saw breakage and provide insights into preventive measures to enhance saw longevity. Key Factors Influencing BreakageSaw Thickness and Keyways:
Monitoring HSS Saw Colors Preventive MeasuresWasher Size and Equal Diameter
Understanding the factors contributing to carbide circular saw breakage is crucial for efficient and safe operation. By addressing key issues such as washer mounting, cleanliness, and proper tightening, operators can significantly enhance the lifespan of their saws. Regular inspections, maintenance, and adherence to recommended operating practices are vital to preventing breakage and ensuring optimal performance in various metalcutting applications.
The number of flutes on a carbide end mill significantly influences its performance across various machining applications. How many flutes do you need? The simple answer: It depends. Obviously there are a quite a number of other factors that impact an end mills performance such as helix angel, edge prep, gullet depth and radius. We can't tackle everything in this article, but hopefully this helps you get a better understanding of why there are different numbers of flutes on end mills. Below is an overview of the advantages and disadvantages associated with end mills featuring different flute counts, along with recommendations for materials based on ISO 513 categories (P, M, K, N, S, H) Single Flute End Mills
2-Flute End Mills
3-Flute End Mills
4-Flute End Mills
5-Flute End Mills
6-Flute End Mills
7-Flute End Mills
8-Flute End Mills
0-Flute End Mills
Advantages of Higher Flute Counts in |
Technical Support BlogAt Next Generation Tool we often run into many of the same technical questions from different customers. This section should answer many of your most common questions.
We set up this special blog for the most commonly asked questions and machinist data tables for your easy reference. If you've got a question that's not answered here, then just send us a quick note via email or reach one of us on our CONTACTS page here on the website. AuthorshipOur technical section is written by several different people. Sometimes, it's from our team here at Next Generation Tooling & at other times it's by one of the innovative manufacturer's we represent in California and Nevada. Archives
March 2024
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