Uncovered – 5 ways you may be killing your end mill!
End mills are important parts of your milling machines. These rotating cutting tools serve a number of purposes from making shapes and holes to profiling, contouring and other drilling applications. As usage persists, your end mill may become dull, blunt, deformed or even break. The best machinists know that a blunt or deformed too can limit productivity, accuracy and precision. If you’re to keep your end mills at top shape, you will need to know all the things you could be doing to damage them. Today, we uncover 7 ways that you may unknowingly be killing your end mills.- Thin Wall Milling
1. Running at the wrong speed Before you start running your machine, it is very important that you have an idea of the appropriate speed for the project. Running your tool too fast predisposes you to having a tool failure or less-than-optimal chip size. Too slow may also mean rough finish that is devoid of accuracy or may result in a deflection. Whatever the case may be, running too fast or too slow can have adverse effects on your end mill
2. Not using High efficiency milling There are many views when it comes to roughing techniques. While traditional roughing is usually preferred for its optimal delivery and performance, Higher efficiency milling generally delivers better output. This is because HEM techniques are optimized to spread wear uniformly, disperses heat and has a far lower rate of tool failure. Using HEM allows for prototype plastic parts because of this uniform approach, lower radial depth of cut and higher axial depth of cut. Traditional roughing on the other hand doesn’t spread wear uniformly and may leave some parts of your end-mill chipped than others.
3. Improper feed rates Although feed rate may vary from job to job, running your end mill too slow of the feed rate can greatly accelerate your tool wear. When you run your end mill tool at a rate too fast for the feed, you are also more likely to get a tool break of fracture.
4. Poor tool handling Improper tool handling may cut across your general maintenance of your tools or your ability to position and time parameters such as feed and speed rate. It can also refer to the inability or constant failure to have a firm connection between the machine and the end mill being in use. A poor machine-tool connection will not only lead to instances of tool pull outs, run outs or scraped parts, but will most likely also affect the material or surface you are working on. Asides frequent cleaning and maintenance of your tooling parts, strive to have more points of contact between your tool shank and tool.
5. Not coating your end mill and prototype plastic parts The benefits of a properly coated tool part are innumerable. A tool that is properly coated to matched the type of jobs it is used on will have a longer life span than its bare counterparts. Coating slows natural wear and tear in your tools because of the added lubricity. Some forms of coating may also deliver more strength to the tool and provide abrasion resistance. Although the price of coating all your tools may be initially heavy on the pocket, the prolonged life span will see you get value for money with reduced maintenance cost, no breakage, chip packing or cutting-edge build-up to deliver excellent performance on all your projects.