Six Milling Troubles (and How To Avoid Them)

March 7, 2018 4:10 pm


Milling jobs present any number of challenges. Here, we break down six of the most common difficulties and share simple ways you can overcome them–make the most of your tools and get parts done right the first time.

1. Vibration

Vibration issues can happen from weak fixtures or work-pieces or simply by using the wrong cutting data or insert. The solution may be as simple as reducing the cutting speed or changing the cutting depth.

2. Chip jamming

Chip jamming is a common obstacle when full slotting, especially in long-chipping materials, and causes insert corner damage, edge chipping, breakage and re-cutting of chips.

3. Poor surface finish

Surface finish can be of critical importance. Don’t risk scrapping components. If you are dissatisfied with your surface finish, you may need to decrease the feed rate per revolution or try a Wiper insert.

4. Burr formation

Problematic with full slotting and pocketing in titanium, but also when milling deep cavities and pockets on vertical machines. Troubles include fractures to the cutting edge, chip jamming and more.

5. Machine power

Power requirements vary depending on amount of metal removal, average chip thickness and cutting geometry. It could require changing the pitch on your milling cutter or changing your depth of cut.

6. Tool wear

Premature tool wear can be caused by a feed rate that is too low to cutting speed that is high. See how to avoid flank, crater and notch wear, thermal cracking and built-up edge to get more from your inserts.

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