Professional Documents
Culture Documents
Milling Cutters
Metal Removal
Cutting-Tool Materials
Metal Removal Methods
Machinability of Metals
and Operations
Single Point Machining
Turning Tools and Operations
Turning Methods and Machines
Grooving and Threading
12.1 Introduction
The two basic cutting tool types used in the metal working industry are of the
Shaping and Planing
single point and multi-point design, although they may differ in appearance and
in their methods of application. Fundamentally, they are similar in that the
Hole Making Processes
action of metal cutting is the same regardless of the type of operation. By
Drills and Drilling Operations
grouping a number of single point tools in a circular holder, the familiar milling
Drilling Methods and Machines
cutter is created.
Boring Operations and Machines
Milling is a process of generating machined surfaces by progressively remov-
Reaming and Tapping
ing a predetermined amount of material or stock from the workpiece witch is
advanced at a relatively slow rate of movement or feed to a milling cutter rotating
Multi Point Machining
at a comparatively high speed. The characteristic feature of the milling process is
Milling Cutters and Operations
that each milling cutter tooth removes its share of the stock in the form of small
Milling Methods and Machines
individual chips. A typical face milling operation is shown in Figure 12.1.
Broaches and Broaching
Saws and Sawing
Abrasive Processes
Grinding Wheels and Operations
Grinding Methods and Machines
Lapping and Honing
ter Tooth
iame
ded Tooth face
Secondary clearance
tsi
Ou Radial
eter Gash angle rake angle
Root diam
Primary clearance
and four fluted cutters with one orientation of the tooth face, and the
end cutting edge that extends past relief to prevent rubbing on the land.
the center of the cutter can also be The terms defined below and illus-
fed directly into solid material. trated in Figures 12.7a and 12.7b are
FIGURE 12.5a: Various single- and double- Solid end mills are double or important and fundamental to milling
ended HSS end mills. (Courtesy The Weldon single ended, with straight or ta- cutter configuration.
Tool Co.) pered shanks. The end mill can be Outside Diameter: The outside di-
of the stub type, with short cut- ameter of a milling cutter is the diam-
ting flutes, or of the extra long eter of a circle passing through the
type for reaching into deep cavi- peripheral cutting edges. It is the
ties. On end mills designed for dimension used in conjunction with the
effective cutting of aluminum, spindle speed to find the cutting speed
the helix angle is increased for (SFPM).
improved shearing action and Root Diameter: This diameter is
chip removal, and the flutes may measured on a circle passing through
be polished. Various single and the bottom of the fillets of the teeth.
double-ended end mills are Tooth: The tooth is the part of the
shown in Figure 12.5a. Various cutter starting at the body and ending
tapered end mills are shown in with the peripheral cutting edge. Re-
Figure 12.5b. placeable teeth are also called inserts.
Special End Mills: Ball end Tooth Face: The tooth face is the
mills (Fig. 12.6a) are available surface of the tooth between the fillet
in diameters ranging from 1/32 and the cutting edge, where the chip
to 2 1/2 inches in single and slides during its formation.
double ended types. Single pur- Land: The area behind the cutting
FIGURE 12.5b: Various tapered HSS end mills.
(Courtesy The Weldon Tool Co.) pose end mills such as Woodruff edge on the tooth that is relieved to
key-seat cutters, corner rounding avoid interference is called the land.
cutters, and dovetail cutters Flute: The flute is the space pro-
(Fig.12.6b) are used vided for chip flow between the teeth.
on both vertical and Gash Angle: The gash angle is
FIGURE 12.6: (a) Ball-nose end-milling cutters are horizontal milling measured between the tooth face and
available in diameter ranging from 1/32 to 2 machines. They are the back of the tooth immediately
inches. (Courtesy The Weldon Tool Co.) (b) HSS usually made of high ahead.
dovetail cutters can be used on both vertical and speed steel and may Fillet: The fillet is the radius at the
horizontal milling machines. (Courtesy Morse have straight or ta- bottom of the flute, provided to allow
Cutting Tools) pered shanks. chip flow and chip curling.
The terms defined above apply pri-
12.3 Milling marily to milling cutters, particularly
Cutter to plain milling cutters. In defining
Nomenclature the configuration of the teeth on the
As far as metal cutter, the following terms are impor-
cutting action is tant.
concerned, the per- Peripheral Cutting Edge: The cut-
tinent angles on ting edge aligned principally in the
the tooth are those direction of the cutter axis is called the
that define the con- peripheral cutting edge. In peripheral
figuration of the milling, it is this edge that removes the
(a) (b) cutting edge, the metal.
(a) (b)
FIGURE 12.8: A variety of indexable FIGURE 12.10: (a) Face milling cutter with wedge clamped indexable inserts.
milling cutters. (Courtesy Ingersoll (Courtesy Iscar Metals, Inc.) (b) Face milling cutters with indexable inserts and
Cutting Tool Co.) wedge clamped milling cartridges. (Courtesy Greenleaf Corp.)
Face Cutting Edge: The face cut- axis. is used to support the insert, the wedge
ting edge is the metal removing edge Axial Rake Angle: The axial rake must absorb all of the force generated
aligned primarily in a radial direction. angle is measured between the periph- during the cut. This is why wedge
In side milling and face milling, this eral cutting edge and the axis of the clamping on the cutting face of the
edge actually forms the new surface, cutter, when looking radially at the insert is preferred, since this method
although the peripheral cutting edge point of intersection. transfers the loads generated by the cut
may still be removing most of the Blade Setting Angle: When a slot through the insert and into the cutter
metal. It corresponds to the end cut- is provided in the cutter body for a body. Both of the wedges clamping
ting edge on single point tools. blade, the angle between the base of the methods are shown in Figure 12.9.
Relief Angle: This angle is mea- slot and the cutter axis is called the The wedge clamp system however,
sured between the land and a tangent blade setting angle. has two distinct disadvantages. First,
to the cutting edge at the periphery. the wedge covers almost half of the
Clearance Angle: The clearance 12.4 Indexable Milling Cutters insert cutting face, thus obstructing
angle is provided to make room for The three basic types of milling opera- normal chip flow while producing pre-
chips, thus forming the flute. Nor- tions were introduced earlier. Figure mature cutter body wear, and secondly,
mally two clearance angles are pro- 12.8 shows a variety of indexable mill- high clamping forces causing clamp-
vided to maintain the strength of the ing cutters used in all three of the basic ing element and cutter body deforma-
tooth and still provide sufficient chip types of milling operations (Fig. 12.2). tion can and often will result. The
space. There are a variety of clamping sys- excessive clamping forces can cause
Radial Rake Angle: The radial tems for indexable inserts in milling enough cutter body distortion that in
rake angle is the angle between the cutter bodies. The examples shown some cases when loading inserts into a
tooth face and a cutter radius, mea- cover the most popular methods now in milling body, the last insert slot will
sured in a plane normal to the cutter use: have narrowed to a point where the last
insert will not fit into the body. When
12.4.1 Wedge this occurs, several of the other inserts
Insert
Clamping already loaded in the milling cutter are
Milling inserts have removed an reset. Wedge clamping
been clamped using can be used to clamp individual inserts
wedges for many years (Fig. 12.10a) or indexable and replace-
in the cutting tool in- able milling cutter cartridges as shown
dustry. This principle in Figure 25.10b.
is generally applied in
one of the following 12.4.2 Screw Clamping
ways: either the wedge This method of clamping is used in
is designed and ori- conjunction with an insert that has a
ented to support the in- pressed countersink or counterbore. A
Clamping Support and torque screw is often used to eccentri-
clamping
sert as it is clamped, or
wedge cally mount and force the insert
wedge the wedge clamps on
the cutting face of the against the insert pocket walls. This
FIGURE 12.9: Two methods of wedge clamping indexable insert, forcing the insert clamping action is a result of either
milling cutter inserts. against the milling offsetting the centerline of the screw
body. When the wedge toward the back walls of the insert
Cutter Cutter
Angular-land Parallel-land
chamber chamber
Workpiece Workpiece
reasons alone, a nose radius insert can be applied. Depending both on the normally will be produced regardless
should be the first choice for any appli- chamfer angle and the lead angle of the of the insert face runout. Parallel-land
cation where it can be used. cutter body in which the insert is used, inserts also make excellent roughing
Inserts with nose radii can offer tool the land of the chamfer will be either and general purpose inserts for posi-
life improvement when they are used parallel or angular (tilted) to the direc- tive/negative and double positive cut-
in 0 to 15 degree lead angle cutters, as tion of feed, as shown in Figure ters. When a parallel land chamfer
shown in Figure 12.15b. When a 12.16a. insert is used for roughing, the land
chamfer is used, as in the left drawing, Inserts that are applied with the width should be as small as possible to
the section of the chip formed above chamfer angular to the direction of reduce friction.
and below point A, will converge at feed normally have only a single cham- Sweep Wipers: Sweep wipers are
point A, generating a large amount of fer. These inserts are generally not as unique in both appearance and applica-
heat at that point, which will promote strong and the cost is usually higher tion. These inserts have only one or
faster than normal tool wear. When a than inserts that have a large nose two very long wiping lands. A single
radius insert is used, as shown in the radius. Angular-land chamfer inserts sweep wiper is used in a cutter body
right drawing, the chip is still com- are frequently used for general purpose filled with other inserts (usually rough-
pressed, but the heat is spread more machining with double negative cut- ing inserts) and is set approximately
evenly along the cutting edge, result- ters. 0.003 to 0.005 inches higher than the
ing in longer tool life. Inserts designed to be used with the other inserts, so that the sweep wiper
The major disadvantage of an insert chamfer parallel to the direction of alone forms the finished surface.
with a nose radius is that the surface feed may have a single chamfer, a The finish obtained with a sweep
finish it produces is generally not as single chamfer and corner break, a wiper is even better than the excellent
good as other common corner geom- double chamfer, or a double chamfer finish attained with a parallel land
etries. For this reason, inserts with and corner break. The larger lands are chamfer insert. In addition, since the
nose radii are generally limited to referred to as primary facets and the edge of the sweep wiper insert is excep-
roughing applications and applications smaller lands as secondary facets. The tionally long, a greater advance per
where a sweep wiper insert is used for cost of chamfers, in relation to other revolution may be used. The sweep
the surface. A sweep wiper is an insert types of corner geometries, depends wiper also offers the same easy set-up
with a very wide flat edge or a very upon the number of facets. A single as the parallel-land insert.
large radiused edge that appears to be facet insert is the least expensive, Sweep wiper inserts are available
flat. There is usually only one wiper while multiple facet inserts cost more with both flat and crowned wiping
blade used in a cutter and this blade because of the additional grinding ex- surfaces. The crowned cutting edge is
gets its name from its sweeping action pense. Figure 12.16b shows two preci- ground to a very large radius, usually
that blends the workpiece surface to a sion ground indexable milling cutter from three to ten inches. The crowned
very smooth finish. inserts. A face milling cutter with six cutting edges eliminate the possibility
Inserts with nose radii are not avail- square precision ground indexable of saw-tooth profiles being produced
able on many double positive and posi- milling cutter inserts was shown in on the machined surface because the
tive/negative cutters because the clear- Figure 12.10a. land is not exactly parallel to the direc-
ance required under the nose radius is The greatest advantage of using in- tion of feed, a condition normally
different from that needed under the serts with the land parallel to the direc- caused by spindle tilt. On the other
edge. This clearance difference would tion of feed is that, when used cor- hand, sweep wipers with flat cutting
require expensive grinding procedures rectly, they generate an excellent sur- edges produce a somewhat better finish
that would more than offset the other face finish. When the land width is if the land is perfectly aligned with the
advantages of nose radius inserts. greater than the advance per revolu- direction of feed.
Chamfer: There are two basic ways tion, one insert forms the surface. This
in which inserts with a corner chamfer means that an excellent surface finish
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