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Maximize Metal Removal Rates with High-Feed Machining Strategies

The combination of high-feed geometry tooling and proper machining strategies can dramatically decrease the time needed to remove material – especially in Die & Mold applications. It can also reduce the number of processes, providing the programmer the flexibility of removing

   

 

Milling Methods
Melin Tool Milling Methods

Is Climb Milling (Down Milling) best for ALL applications? For most applications, it is. It provides easier chip evacuation, because the chips are removed in a direction behind the cutting edge, generating less heat. Conventional Milling (Up Milling) is better for milling castings and forgings, or high hardness workpiece materials. 

One of the more important advantages climb milling has, is that it provides freer machining which results in requiring much less horsepower to make efficient cuts.

Climb Milling vs. Conventional Milling - Below is a comparison of these two basic machining styles: 

Climb Milling (Down Milling) - This type of end milling is enacted when the tool's rotation pulls in the same direction as the workpiece's feed movement. The flute of end mill enters the workpiece at maximum chip thickness and exits the cut at zero chip thickness. This is the beginning of chip thinning theory explained later.Easier chip evacuation because chips are removed in a direction behind the cutting edge which generates less heat and increases tool life. This results in better finishes due to not re-cutting chips. Freer or less pressured machining consumes less horse power (hp). Chip thickness (Ct) starts at maximum then decreases. Can increase tool life by as much as 50%. Reduces risk of work hardening.

Conventional Milling (Up Milling) - This type of end milling occurs when the tool's rotation pushes opposite of the workpiece's feed movement. The flute of the end mill enters the workpiece at minimum chip thickness and exits the cut at maximum chip thickness. Difficult chip evacuation because chips fall in front of cutting tool's path causing re-cutting of chips resulting in a poor surface finish. Requires more horsepower (HP) because of rubbing action between cutting tool, chips, and workpiece material. Chip thickness (Ct) starts at minimum and increases. Preferred for milling castings, forgings, hot rolled, as well as other hard, or high BHN, workpiece materials. Method prevents chipping out of the machined materials. Tendency to lift part because of the direction of cutting tool rotation.
   

 

Tool Holder Selection
Melin Tool - Tool Holders

Selecting an appropriate Tool Holder style for the job at hand is critical for high performance success. Increasingly, shrink fit holders and special “safety lock” shanks are used in larger production runs.  While implementing their use has sizable cost, the benefits they provide with the higher metal removal rates they deliver can pay back the investment fairly quickly.  For small to medium runs, especially high accuracy work, we suggest using milling chucks and hydraulic holders.  The additional rigidity and trueness helps get the most from the HIGH Performance cutting tools.


Melin Tool - Tool Holder Attributes

 

Using Common Shanks
H6 Tolerance Shanks from Melin Tool
Why require H6 tolerance common shanks?
For optimum efficiency and maximum holding strength, many tool setups are using shrink fit holders and milling chucks.

H6 tolerances provide a more accurate tool because they are specific to the shank diameter, rather than being a universal tolerance for all diameters. This enables a “truer” surface bond to the holder and higher feed rates to be possible.

Common shanks with an appropriate surface finish (not too polished, to avoid slippage) are the most cost efficient way to minimize the number of tool holders required to inventory. Fewer shank diameters, fewer holders!


Tool Reconditioning
Reconditioning Cutting Tools and Drills from Melin Tool

Proper Tool Reconditioning CAN Make a “World of Difference.”

Many users find a reduction in performance results of their reground high performance drills when comparing them to a new tool. Sometimes, the difference is so dramatic that cutting parameters for the whole job are cut back to accommodate an average performance of both new and reground tool.

The two biggest causes for this are that the service supplier wasn’t able to match the specific geometries of the original tool or that they could not replicate the coating of the original new tool.

To assure your reground tools meet the performance of a new tool, contact your drill manufacturer to find out where authorized reconditioning services for their drills are available (preferably trained by the manufacturer) AND where the exact coating of the new tool can be provided as a recoating service.

It’s not the least expensive way to recondition your drills or tools, but it will
reduce machining timein your spindles and that will save you far more money.


Trochoidal Milling
trochoidal milling Use Trochoidal Milling for efficient machining in pocketing operations. Use a constant circular interpolation movement at full axial depth and small radial depth of cut. This will allow you to run at much higher cutting speeds and feed rates, which will enable you to remove material much faster. Using this method, you will also be able to use a single end mill for machining several different slot widths. This means FEWER tool changes.

nACo & nACRo Coatings
nACo and nACRo Coating Chart

nACo
(Aluminum Titanium Nitride plus Silicon Nitride) and nACRo (Aluminum Chrome Nitride plus Silicon nitride) coatings have higher heat resistance and provide higher lubricity than AlTiN, TiAlN, & TiCN. Proven to delivery longer tool life on Titanium Alloys, Stainless & Steel Alloys and Nickel Based Alloys, many programmers use this advantage on short productions to increase feed rates even further, since the coating is able to handle the heat generated.

Although
nACo coating can be used on all ferrous materials, it is most effective on Steel Alloys. nACRo coating can also be used on all ferrous materials, but it shows its superiority on Titanium Alloys, Stainless Steels and Nickel Based Alloys
nACo and nACRo Coated Tools


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Phone: (800) 521-1078 or (216) 362-4200 •Fax: (800) 521-1558 or (216) 362-4230
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