Processing of Carbide End Mills

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Charlotte Barnett
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1 Processing of Carbide End Mills Table of contents 1. Job Definition 4 2. Parameters and machine data 4 3. Some charts Comparison cutting edge cutting corner at different speed Amount of mountings Different directions Rounding of the cutting edge with different speed Rounding of the cutting edge with HSC1/ Different measuring points at the cutting edge in relation to the sense of rotation _ Immersion depths Increased tool life in relation to cutting edge preparation Smoothing of the flute (meanwhile K3/4 was replaced by H4/4) Jaggedness at the cutting edge (Media: HSC 1/3) 17 Page 1 of 17

2 Processing of End Mills (HM) When rounding the cutting edges of end mills, the following needs to be considered: Rounding of the cutting edge should not be larger than 3 µm, except of ball nose end mills The cutting corner should not be rounded more than 3% of the main cutting edge. To avoid a built-up edge, especially when processing titanium and aluminium, a polished tool is benefiting. Using HSC 1/3, a cutting edge of a maximum of 16 µm at carbide end mills can be achieved. The cutting corner of the tool will not be rounded significantly more. Using HSC 4/4 or M4/3 for carbide tools, a cutting edge of 1 µm can be achieved during polishing (max. 2 minutes). Processing the tool in just cutting direction, a k-factor of larger than 1 can be achieved. The actual process time depends on the carbide grade (fine grain needs probably a longer process time) as well as on the amount of cutting edges. Generally the process time is the most reasonable parameter to achive larger or smaller rounding. For sure also the choice of processing media is mayor important. The influence of the process parameters for rounding and jaggedness can be described as follows: Rounding: - Process time: ca. 4% - Speed rotor: ca. 3% - Speed holder: ca. 2% - Sense of direction: 1% (into cutting direction: more rounding) Jaggedness: - Process time: ca. 15% - Speed rotor: ca. 5% - Speed holder: ca. 15% - Sense of direction: 23% (against cutting direction: smoother) Page 2 of 17

3 Measuring point at the main cutting edge Measuring point at the cutting corner Page 3 of 17

4 1. Job Definition Rounding of the cutting edges to 6 µm 3 µm Recommended rounding at the cutting edge (e.g.: end mill, diameter 1 mm): Processing of wood: 4 to 6 µm Processing of aluminium/titanium 6 to 8 µm Processing of steel 1 to 25 µm Processing of ball nose end mills to 3 µm 2. Parameters and machine data Tool Ø Rounding of the cutting edge before processing (µm) Rounding of the cutting edge after processing (µm) Media Speed rotor [min-1] End mill 5 4,3 29,8 TZM 2/3 4 2 End mill HSC 1/ End mill 7 1,2 8 HSC 1/ End mill 7 3,5 1,8 HSC 1/ End mill 7 2,9 14,8 HSC 1/ End mill 8 3,9 12 TZM 2/ End mill ,4 HSC 1/ End mill 1 2,5 21,8 TZM 4/ End mill 1 2,4 26,9 TZM 4/ End mill 12 3,7 15,8 HSC 1/ End mill 2 3,9 14,9 HSC 1/ End mill 2 5,7 27,9 TZM 4/ End mill 1 8,9 H4/ Droplet removal at end mill HSC 1/ Speed holder [min-1] Direction of rotor 3 sec right, 12 sec left Time (min.) Holders angled Yes/No 4 N Max. 8 N Max. 3 N Max. 5 N Max. 12 N Max. 1 N Max. 12 N Max. 4 N Max. 6 N Max. 12 N Max. 12 N Max. 7 N Max. 15 Y Max. 2,5 N Max. Immersion depth Page 4 of 17

5 Measuring the cutting edge Cutting edge before processing Cutting edge after processing Rounding of the cutting edge Page 5 of 17

6 Average Radius [µm] 3. Some charts 3.1. Comparison cutting edge cutting corner at different speed Cutting corner and -edge HSC1/3 DF-4 Tools w/o additional DF 4 Tool drive, w/o add. right, drive; H4/4, rotor: Rotor=4min-1, 45 rpm; holder: fast 96 driven rpm; holder, r/l,; immersion endmill depth=15 (1mm, mm; carbide) carbide end mill Ø1 mm Cutting edge Cutting corner Process time [min] Page 6 of 17

7 Rounding of the cutting edge [µm] 6 Rounding with QZ TZM 1-34/5 DF 4 Tool w/o add. drive; rotor: 45 rpm; holder: 96 rpm; r/l,; immersion depth=18 mm; carbide end mill Ø1 mm DF-Tools w/o add.drive, slow driven holder, Immersion depth=18mm nrotor=45min-1, 5-direction, end mill (d=1, carbide) Process time [min] Cutting corner Cutting edge Page 7 of 17

8 Process time [min] 3.2. Amount of mountings Comparison fully loaded holder - just one end mill loaded DF Tool w/o DF-Tools addit. drive; w/o add.drive, TZM 2/3, K3/4 rotor direction: Immersion clockwise; depth=18mm end mill diam. 1 mm right rotation, immersion end mill (d=1, depth=15mm carbide) 25 2 n=35, one end mill n=5min-1, one end mill n=35min-1, holder fully loaded n=5min-1, holder fully loaded Average Radius [µm] Page 8 of 17

9 Average Radius [µm] 3.3. Different directions Rounding of the cutting edge at different senses of rotation. DF 4 Tools DF-4 w/o Tools addit. w/o drive; add. process drive 2min, time 2min, n=4 speed=45 rpm, fast driven rpm, immersion holder, depth = right, immersion 15mm, right depth= left rotation 15mm, 5:5o; QZ 1-2, TZM 4/5 9 end carbide mill (carbide, end mill diameter Ø 1), 1 mm, Left Right Cutting edge Cutting corner Page 9 of 17

10 Average Radius [mm] 3.4. Rounding of the cutting edge with different speed 25 Cutting edge - different speed DF-Tool w/o add. drive, left, end mill (1mm, carbide), Rotor=4 rpm, fast holder, HSC1/ n=2min Process time [min] n=4min-1 Page 1 of 17

11 Rounding of the cutting edge [µm] 3.5. Rounding of the cutting edge with HSC1/3 16 Rounding of the cutting edge with HSC 1/3 DF-4 Tools with additional drive, fast holder, right, immersion depth=15mm, Rotor=45 rpm, endmill (1mm, carbide) Process time [min] Cutting edge Cutting corner Cutting corner Logarithmic Logarithmic Page 11 of 17

12 Rounding of the cutting edge [µm] 3.6. Different measuring points at the cutting edge in relation to the sense of rotation Rounding of the cutting edge at measuring points a and b DF-4 Tools w/o add. drive, H4/4, n=2 rpm, immersion depth=15mm, right rotation, end mill (carbide, Ø1) Process time [min] Measuring point a Measuring point b Page 12 of 17

13 Rounding of the cutting edge [µm] 2 Rounding of the cutting edge at measuring points a and b DF-4 Tools w/o add. drive, H4/4, n=2 rpm, immersion depth=15mm, left rotation, end mill (carbide, Ø1) Process time [min] Measuring point a Measuring point b Page 13 of 17

14 Average Radius [µm] 3.7. Immersion depths Immersion depth DF Tool w/o add DF drive, Tool n=2min-1, w/o addit. 1% Drive; left, speed= slow holder 45 (SL) rpm QZ 1-2, r/l 5:5 cutting TZM edge, 2/3; drill (carbide, end Ø1) mill diam. 1 mm Immersion depth=15 mm Immersion depth=2 mm Process time [min] Page 14 of 17

15 3.8. Increased tool life in relation to cutting edge preparation Page 15 of 17

16 Surface roughness Ra [µm] 3.9. Smoothing of the flute (meanwhile K3/4 was replaced by H4/4) Special tool diameter=32mm DF-Tools with angled holders, K3/4, 2min, 9%left rotation, up- and down movement 2mm, nrot=3rpm, speed holder=135 rpm,2,18,16,14,12,1,8,6,4,2 Before processing After processing Page 16 of 17

17 Jaggedness [µm] 3.1. Jaggedness at the cutting edge (Media: HSC 1/3) Jaggedness HM- Endmill 1,,8,6,4,2, Process time [min] n=2, Left Page 17 of 17

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