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Complete concept about getting the best use of cutting tools

“Technical Applications Center” is dedicated into constructing milling statistics for customers to use DHF endmills in its best way. To provide strong assistance, DHF is an original manufacture, extending its depth from design, produce, selling and after-care service for valued customers.

Well use the endmills is a professional knowledge, normally milling statistics given by ordinary suppliers is likely based on ratiocination within endmills’ diameter to infer Cutting (v) m/min, Feed (f) mm/tooth, Depth of Cut (Aa) and Width of Cut (Ap).
By explaining in this way would bring confusion to users and users couldn’t realize the ultimate efficiency of end mills.

On the contrary, the practical milling statistics provided by Technical Applications Center varies from different kinds of work material users, it guides customer to comprehend of cutting proceeding.

Below is a sample picture from DHF practical milling statistics: 
 

To achieve the greatest use of endmills, the following six steps need to be fully
cooperated to perform its best way of use.

Instruction as below:
1. Before processing, be sure to know about the machine’s rigidity and spindle’s horsepower.
1kw= 0.75 HP
a. The machine belongs to guide rail or linear rail. (The rigidity is better in guide rail.)
b. Transmission to Spindle comes from gear, direct-drive, built-in motor and belt.
   (The former is better in torque than latter.)
c. Cutter bars of Spindle are classified into BT (SK30), BT40 (SK40), BT50 (SK50) and HSK (High Speed Spindle).
   Due to different operations for diverse machines, working ability and milling statistics are dissimilar as well.

2. How to use cutter holder correctly:
a. During the high-efficiency processing, be sure to use high-rigidity holder to hold the cutters for reducing the cutters’ vibration. It may gain its highest efficiency and extend tool life.
b. When processing by high speed, it must to be used high accuracy and match spindle’s dynamic balance, in order to reduce deviation of cutters.

3. Choose the suitable cutters and coatings:
a. DHF has 11 series and over two hundred typed, with geometric, angle, raw material to apply each different usage. Because of the differences from work materials’ attributions to hardness, pick the suitable cutters to match the right material, design and coating.
b. Coating is for reducing wear and friction which extend the time-limits and increase the cutter speed, it improve smooth of surface and depend on different work materials it can match up to suitable
c. Coating may fit for disparate types and attributions, and the coolant way is divided into wet and dry processing.

4. Pay attention to the run out and apply the correct milling statistics:


a. Cutter’s run out may affect not only tool-change times but the roughness of material being milled.
b. Cutters made of different designs are for different ways to process. Applying the correct milling statistics is quite important.
c. The milling statistics may adjust by different elongation. (When the elongation is getting longer, the milling statistics would decrease.)          

5. Correct ways to material removal in cooling:
a. There’s different ways in cooling: Dry machining, emulsion machining, oil machining, mist
b. Different coatings and features have different coolant types. According to the test report of Technical Applications Center, tools’ life may have 20-30% differences between dry coolant and wet coolant, when coating and milling type remain the same. Therefore, choose the right coolant type would reach the ideal tool’s life.
c. The proper design takes heat away by chip removal when milling, not only to prevent the working material deformed, but also approach the suitable cooling result.
d. Cooling is not only to lower the temperature of working material and cutters, but also to remove the chip smoothly. It’s very important to have the cooling position aimed at cutter flue when removing chips.

6. In processing, milling sound can be distinguished from wrong:
a. The milling sound is smooth while applying the correct milling statistics, so it can optimize tool life, if not, it can cause decrease the time for tool using.
1. When the sound is piercing, please lower Spindle rotation rate (S) and movement of feed (Feed).
2. When the sound is raucous, please speed up Spindle rotation rate (S) and movement of feed (Feed).
3. When the sound is becoming smaller and stable than before, it means the operation is getting close to ideal milling statistics.
The competitiveness of enterprise is from proper cutter selection and practical applications. Moreover, increase the production capacity and lower the human and material costs at the same time could decide the success and future of enterprise.

Written by DHF Technology Center

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