Adjusting the cutting parameters of a 3 Flutes Roughing End Mill according to the material is a crucial aspect of achieving optimal machining results. As a supplier of high - quality 3 Flutes Roughing End Mill, I understand the significance of getting these parameters right. In this blog, I'll share some in - depth knowledge on how to make these adjustments based on different materials.
Understanding the Basics of Cutting Parameters
Before delving into material - specific adjustments, it's essential to understand the main cutting parameters. These include cutting speed (Vc), feed per tooth (fz), and axial and radial depth of cut (ap and ae respectively).
Cutting speed is the speed at which the cutting edge of the end mill moves relative to the workpiece. It is usually measured in meters per minute (m/min). Feed per tooth is the distance the end mill advances for each tooth during one revolution, measured in millimeters per tooth (mm/z). Axial depth of cut is the depth of the cut in the axial direction of the end mill, and radial depth of cut is the depth of the cut in the radial direction.
Adjusting for Aluminum
Aluminum is a common material in the machining industry due to its light weight, good corrosion resistance, and high machinability. When using a 3 Flutes Roughing Milling Cutter on aluminum, we can generally set relatively high cutting speeds. A cutting speed in the range of 200 - 400 m/min is often suitable. This high speed helps to prevent the aluminum from sticking to the cutting edges of the end mill, which can cause poor surface finish and tool wear.
The feed per tooth for aluminum can be set at around 0.1 - 0.3 mm/z. Since aluminum is a soft material, a larger feed per tooth can be used to increase the material removal rate. For the axial depth of cut, it can be up to 3 - 5 times the diameter of the end mill, and the radial depth of cut can be around 0.1 - 0.2 times the diameter of the end mill.
Adjusting for Steel
Steel is a much harder material compared to aluminum, and thus requires different cutting parameters. The cutting speed for steel is typically lower than that for aluminum. For mild steel, a cutting speed of 60 - 120 m/min is a good starting point. As the hardness of the steel increases, the cutting speed should be further reduced.
The feed per tooth for steel is usually in the range of 0.05 - 0.2 mm/z. A smaller feed per tooth is used to avoid excessive cutting forces that could lead to tool breakage. The axial depth of cut for steel can be around 1 - 2 times the diameter of the end mill, and the radial depth of cut can be around 0.05 - 0.1 times the diameter of the end mill.
Adjusting for Stainless Steel
Stainless steel is known for its high strength and corrosion resistance, but it is also more difficult to machine compared to mild steel. The cutting speed for stainless steel should be relatively low, usually in the range of 30 - 60 m/min. This is because stainless steel has a high work - hardening tendency, and high cutting speeds can cause the material to harden rapidly, increasing tool wear.
The feed per tooth for stainless steel can be set at around 0.03 - 0.15 mm/z. Similar to steel, a smaller feed per tooth helps to control the cutting forces. The axial depth of cut can be around 0.5 - 1.5 times the diameter of the end mill, and the radial depth of cut can be around 0.03 - 0.08 times the diameter of the end mill.
Adjusting for Cast Iron
Cast iron is a brittle material with good damping properties. When machining cast iron with a 3 Flutes Roughing End Mill, the cutting speed can be set at around 80 - 150 m/min. The feed per tooth can be in the range of 0.1 - 0.25 mm/z.
The axial depth of cut for cast iron can be up to 2 - 3 times the diameter of the end mill, and the radial depth of cut can be around 0.08 - 0.15 times the diameter of the end mill. Since cast iron contains graphite, which acts as a solid lubricant, it can be machined with relatively higher feed rates compared to some other materials.
Factors Affecting Parameter Adjustment
Apart from the material itself, there are other factors that can affect the adjustment of cutting parameters. The machine tool's power and rigidity play an important role. A more powerful and rigid machine can handle higher cutting forces, allowing for higher cutting speeds and feed rates.
The coolant used also has an impact. Coolants can help to reduce the temperature at the cutting zone, improve the surface finish, and extend the tool life. When using a coolant, it is possible to increase the cutting speed and feed rate slightly.
The tool coating is another factor. Coatings such as TiAlN or TiCN can improve the tool's wear resistance and heat resistance, enabling higher cutting speeds and better performance.
Importance of Fine - Tuning
It's important to note that the parameters mentioned above are just general guidelines. In actual machining, fine - tuning is often required. Start with the recommended parameters and then make small adjustments based on the actual machining situation, such as the surface finish of the workpiece, the tool wear, and the cutting forces.
Conclusion
Adjusting the cutting parameters of a 3 Flutes Roughing End Mill according to the material is a complex but essential task. By understanding the properties of different materials and how they interact with the end mill, we can optimize the cutting process, improve the machining efficiency, and extend the tool life.
As a supplier of 3 Flutes Roughing End Mill, we are committed to providing high - quality products and technical support. If you are looking for reliable 3 Flutes Roughing End Mills or need more advice on cutting parameter adjustment, please feel free to contact us for procurement and in - depth discussions.
References
- Boothroyd, G., & Knight, W. A. (2006). Fundamentals of machining and machine tools. CRC Press.
- Trent, E. M., & Wright, P. K. (2000). Metal cutting. Butterworth - Heinemann.
