Technical Guidance

Endmilling Edition Basics of Endmilling

n Parts of an Endmill

Body Neck Shank

Land width
Cutter sweep Neck Radial relief
diameter Relief width Radial primary
Margin width relief angle
Shank
Diameter Margin Radial secondary
diameter
clearance angle
Neck length
Centre hole
Length of cut Shank length
Overall length

Rake face Rake angle Helix angle

Centre cut
Land width Flute Heel Corner Radial
End cutting edge
Land
cutting edge
End gash

Rounded
flute bottom
Web
Centre hole thickness Axial primary relief angle
Flute depth Chip pocket Axial secondary
clearance angle
Concavity angle of Ball radius
end cutting edge (*)
* Centre area is lower than the periphery

n Calculating Cutting Side milling

D Calculating Cutting Speed
Conditions  vc : Cutting speed (m/min)
(Square Endmill) p x Dc x n 1,000 x vc   p : ≈ 3.14
vc = n = Dc : Endmill diameter (mm)
1,000 p x Dc
  n : Spindle speed (min-1)
D Calculating Feed Rate Per Revolution and Per Tooth  vf : Feed rate (mm/min)
v    f  : Feed rate per revolution (mm/rev)
vf = n x f f = f ap
n   fz : Feed rate per tooth (mm/t)
f vf  Dc   z : Number of teeth
vf = n x fz x z fz = =
z nxz ae
Slotting
D Depth of Cut (D.O.C.)
ap : Axial D.O.C. (depth)
ae : Radial D.O.C. (cutting width)

ap Depth of cut
R
(Ball Endmill) D Calculating Notch Width (D1) ap

D1= 2 x 2 x R x ap – ap 2
Technical Guidance /

D1 øDc
References

pf Pick feed

øDc

DC
 utting speed and feed rate (per revolution and per tooth) ap
R

are calculated using the same formula as square endmill.

D1
pf

N19
 Technical Guidance
Basics of Endmilling Endmilling Edition

n Up-cut and Down-cut D Side Milling D Slotting

fz fz fz

Up-cut

Work Down-cut
Work
material Work
material
Feed Feed Feed material
(a) Up-cut (b) Down-cut

Work Work
material material
Feed Feed

(a) Up-cut (b) Down-cut

D Wear Amount D Surface Roughness D Condition

Work: S50C
Feed Dir. Vertical Dir. Endmill: GSX21000C-2D
0.08 (ø10mm, 2 teeth)
0.07 5 Cutting
Flank Wear Width (mm)

0.06 Conditions: v c=88m/min

Up-cut 4
Rmax (µm)

0.05 Down-cut (N=2800min-1)

Down-cut
0.04 3  vf=530mm/min
0.03 Up-cut
Down-cut Up-cut (fz=0.1mm/t)
0.02 2
0.01 ap=15mm
1 ae=0.5mm
0 50 100 150 200 250
Cutting Length (m) 0 Side Milling
Dry,Air

n Relation Between Side Milling Slotting

Cutting Condition and
Deflection Work: P
 re-hardened steel Work: P
 re-hardened steel
Endmill (40HRC) (40HRC)
Specifications Cutting Cutting
Conditions: v c=25m/min Conditions: v c=25m/min
ap=12mm ap=8mm Up-cut Down-cut
ae=0.8mm ae=8mm

Feed rate Feed rate Feed rate Feed rate

Cat. Number Helix 0.16mm/rev 0.11mm/rev 0.05mm/rev 0.03mm/rev

No. of Teeth Angle Style Style Style Style

Up-cut Down-cut Up-cut Down-cut Up-cut Down-cut Up-cut Down-cut

SSM2080

2 30°
Technical Guidance /
References

SSM4080

4 30°

Cutting
surface · The tool tip tends to back off with the down-cut. · The side of the slot tends to cut into the up-cut side toward the bottom of the slot.
Reference 100µm
Results
surface · 4 teeth offers more rigidity and less backing off. · 4 teeth offers higher rigidity and less deflection.

N20
 Technical Guidance
Endmilling Edition Troubleshooting for Endmilling
n Troubleshooting for Endmilling

Failure Cause Remedies

Cutting
Excessive Wear · Cutting speed is too fast · Decrease cutting speed and feed rate.
Conditions
· Feed rate is too fast
· The flank relief angle is too small · Change to an appropriate flank relief angle
Tool Shape
· Insufficient wear resistance · Select a substrate with more wear
Tool Material
resistance
· Use a coated tool
Cutting Edge Failure

Cutting
· Feed rate is too fast · Decrease cutting speed.
Chipping Conditions
· Cutting depth is too deep · Reduce depth of cut
· Tool overhang is too long · Adjust tool overhang for correct length
· Work clamps are weak · Clamp the work piece firmly
Machine
· Tool is not firmly attached · Make sure the tool is seated in the chuck
Area
properly

Cutting
Tool Fracture · Feed rate is too fast
Conditions
· Cutting depth is too deep
· Tool overhang is too long
· Cutting edge is too long
· Web thickness is too small
Tool Shape
· Decrease cutting speed.
· Reduce depth of cut
· Reduce tool overhang as much as possible
· Select a tool with a shorter cutting edge
· Change to more appropriate web thickness

Cutting · Feed rate is too fast · Decrease cutting speed.

Shoulder Deflection
Conditions · Cutting depth is too deep
· Tool overhang is too long
· Cutting on the down-cut
· Helix angle is large
· Web thickness is too thin
Tool Shape
· Reduce depth of cut
· Adjust tool overhang for correct length
· Change directions to up-cut
· Use a tool with a smaller helix angle
· Use a tool with the appropriate web
thickness

Cutting · Feed rate is too fast

Unsatisfactory · Decrease cutting speed.
Conditions
Machined Surface
Finish · Packing of chips · Use air blow
· Use an insert with a larger relief pocket.
Others

Cutting · Cutting speed is too fast · Decrease the cutting speed

Chattering
Conditions · Cutting on the up-cut
· Tool overhang is too long
· Rake angle is large
· Work clamps are weak
Tool Shape · Tool is not firmly attached
Machine Area
· Change directions to down-cut
· Adjust tool overhang for correct length
· Use a tool with an appropriate rake angle
· Clamp the work piece firmly
· Make sure the tool is seated in the chuck
properly

Cutting
Packing of Chips · Feed rate is too fast · Decrease cutting speed.
Conditions
· Cutting depth is too deep · Reduce depth of cut
· Too many teeth · Reduce number of teeth
Tool Shape
Technical Guidance /

· Packing of chips · Use air blow

References

N21