Kunshan Meiyaxing Hardware Machinery Co., Ltd. is a service-oriented enterprise specializing in the sales and operation of CNC cutting tools. We provide tungsten carbide end mills, end mill inserts, turning inserts, grooving and parting inserts, drilling and boring inserts, multi-functional inserts, threading inserts, and other indexable inserts, along with matching tool holders and cutter heads. We have established long-term and stable strategic partnerships with well-known professional manufacturers of high-efficiency tungsten carbide end mills. The company possesses advanced production equipment from Swiss Rollomatic, German Walter, and Japanese Makino Seiki, as well as German Zoller-Genius 3S and American PG... With 1000 and other testing equipment, relying on our service and operations, and guided by strong R&D and production capabilities, we solve various cutting tool problems for processing and manufacturing enterprises. We aim to become a professional partner offering comprehensive cutting tool solutions and cost optimization services, focusing on optimizing product processing costs to achieve mutual benefit and common development.
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.
I. How to Choose the Right Milling Insert? – A Prerequisite for Timing
Choosing the right insert is a prerequisite for correct use. Incorrect selection can lead to chipping, rapid wear, and even machine tool damage. Three dimensions should be considered when selecting:
1. Material Selection Based on Workpiece Material
· Steel: Choose P-type coated inserts (such as CVD coatings) with good wear resistance, capable of withstanding high temperatures and pressures.
· Stainless Steel/Heat-Resistant Alloys: Use M-type inserts, requiring a sharp cutting edge and excellent resistance to built-up edge.
· Cast Iron: Use K-type inserts, typically made of ceramic or CBN material, requiring extremely high wear resistance.
· 1. Aluminum Alloy/Copper: Use uncoated or DLC-coated inserts with a large rake angle and extremely sharp edges to avoid built-up edge.
2. Select Groove Type Based on Machining Process
* Roughing: Use high-strength groove types such as E and R. Features include a strong cutting edge, large radius, and the ability to withstand large depths of cut and feeds, but the surface finish is generally average.
* Finishing: Use sharp groove types such as F and P. Features include a large rake angle, sharp cutting edge, and light cutting speed, achieving a surface finish below Ra1.6.
* Square Shoulder Milling: Use 90° lead angle inserts to form right-angle sidewalls.
* Face Milling: Use 45° or round inserts. 45° optimizes cutting force distribution, while round inserts are suitable for high-feed milling.
3. Select Precision Based on Machine Tool and Working Conditions
* Roughing: Use tolerance grade M (molded) inserts for high cost-effectiveness.
* Finishing: Use tolerance grade G (ground) inserts for high dimensional consistency, suitable for high-precision machining.
II. Proper Use of Milling Inserts
1. Installation and Inspection
* Cleaning: Thoroughly clean the cutter body's grooves and the insert's underside before installation. Residual chips can cause the insert to tilt, resulting in abnormal chipping.
* Tightening: Use a torque wrench to tighten the screws to the torque specified in the cutter body's instruction manual. Insufficient torque will loosen the insert, while excessive torque may crush the insert or damage the screw.
* Centering: For inserts with a finishing edge, ensure the finishing edge is parallel to the feed direction; for end mills, check that the height of each tip is consistent.
2. Cutting Parameter Settings
* Linear Speed: Refer to the recommended value in the insert sample. Too high a speed will cause hot cracking and rapid wear; too low a speed will result in built-up edge. Generally, start adjusting from the lower limit of the recommended value.
* Feed per Tooth: 0.15-0.4 mm/z for roughing, 0.05-0.15 mm/z for finishing. Note that the feed rate differs significantly between round inserts and square shoulder inserts.
* Depth of cut: For rough machining, the depth of cut should not exceed 70% of the cutting edge length to avoid damaging the tool body.
3. When to use coolant
• Rough machining of steel: It is recommended not to use coolant; use dry cutting + high-pressure air chip removal to avoid thermal cracking of the cutting edge.
• Stainless steel/titanium alloy: High-pressure, high-flow-rate coolant must be used, and the nozzle should be aimed at the chip formation area to help break chips and lubricate.
• Cast iron: Dry cutting.
• Aluminum alloys: Emulsions or minimal lubrication must be used to prevent aluminum chips from melting onto the cutting edge.
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 uniform, expected wear band 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
