Kunshan Meiyaxing Hardware Machinery Co., Ltd. is a direct branch of Hong Kong Meiya International Trading Co., Ltd. in China. It owns its own cutting tool brand: MANF, and engages in the sales and operation services of CNC cutting tools. It provides tungsten carbide end mills, milling inserts, turning inserts, grooving and parting inserts, drilling and boring inserts, multi-functional inserts, threading inserts, and other indexable inserts and their matching tool holders and tool holders. Furthermore, it has established long-term strategic partnerships with many well-known manufacturers, with joint R&D, design, and production teams, advanced equipment, and continuously innovative technological strength. It is committed to mutual cooperation, guided by technical services, forming a mutually supportive industrial chain to solve various processing problems for manufacturing enterprises.
In metal cutting, milling is one of the most widely used machining methods. As the "teeth" that directly participate in cutting, the proper use and precise timing of milling insert replacement directly determine machining efficiency, cost, and workpiece quality. This article will systematically explain the core usage techniques and judgment criteria for milling inserts.
III. When must the insert be replaced or indexed?
Failure to replace worn inserts in a timely manner is the primary cause of tool body scrap and workpiece dimensional deviations. The following are the judgment criteria:
1. Observe the machining sound and vibration
• Normal milling sound is smooth and uniform. When the sound becomes sharp and harsh or periodic dull impact sounds appear, it indicates that the insert is severely worn or chipped.
2. Check the chip morphology
• Normal chips are uniformly curled or C-shaped. If the chip color turns dark blue or purple (when machining ordinary steel), it indicates that the cutting temperature has risen abnormally and the flank wear has exceeded the limit.
• 1. Thin chips on one side and thick chips on the other, or the appearance of granular chips, indicate that individual cutting inserts are damaged.
3. Monitor cutting force and spindle load
* Under the same machining parameters, a continuous increase in spindle load exceeding 15% is usually a signal that the flank wear has reached a uniform wear of 0.3mm or more.
4. Assess workpiece surface quality
* The appearance of chatter marks, burrs, or locally shiny spots on the workpiece surface indicates that the finishing edge has failed.
* Unstable dimensional accuracy, such as a difference in dimensions exceeding 0.03mm between the two ends when milling a 100mm wide surface, indicates inconsistent wear of the cutting inserts.
5. Refer to specific wear values
* Finishing: Indexing is required when the flank wear VB reaches 0.1-0.15mm.
* Roughing: Replace the insert when VB reaches 0.3-0.5mm.
* Chipping: Any visible chipping (exceeding 0.2mm) requires immediate replacement.
IV. Common Faults and Countermeasures
Phenomenon Possible Cause Solution Cutting Insert Chipping Excessive depth of cut, hard spots, brittle insert material: Reduce AP, inspect the blank, and replace with a material with better toughness.
Rapid flank wear: Excessive linear velocity, insufficient cooling: Reduce VC to 70% of the recommended value, increase cooling.
Built edge: Excessive linear velocity, low cutting temperature, sticky material: Increase VC, use coated inserts, or increase cooling.
Cranial groove in the insert center: Excessive cutting temperature, chemical diffusion: Reduce VC, use a coating with stronger anti-diffusion properties.
Tool body and workpiece interference: Poor chip removal. Using high-pressure cooling to assist chip breaking and adjusting climb/convertible milling modes are crucial. Mastering the use and timing of milling inserts essentially involves finding the optimal balance between cost and efficiency. Operators should develop the habit of regularly (e.g., every 20 pieces or every 30 minutes) observing the condition of the inserts, using four "sensors"-sound, chips, load, and surface quality-to make judgments. Timely indexing or replacement when the insert reaches the expected uniform wear zone not only protects the expensive tool body but also ensures stable and efficient machining. Remember: the most expensive insert is the one that has failed but is still being used.
If you have any questions about MANF brand tools, please call us for consultation or negotiation"
Contact us:Company name:Kunshan Meiyaxing Hardware Machinery Co., Ltd;Tel:8618962438699;Address: Room 3003, Building 3, Zhengtailong, No. 1288 Chengbei Middle Road, Kunshan City, Jiangsu Province, China;Email:myxcuttingtools@gmail.com;Website: https://www.myxcuttingtools.com
