Cutting Tool Geometries Mill

A multi-point tool has two or more chip  producing edges on a common body and is  rotated to cut some examples of  multi-point tools include face milling  cutters end mills drills reamers and  taps, let's explore multi-point tools by  focusing on face milling cutters face  milling cutters effectively generate  flat surfaces with the spindle  perpendicular to the work surface the  cutter body has multiple pockets to  accept a variety of indexable insert  types.

As the cutter rotates each insert  edge alternatively enters and leaves the  cut removing a small amount of material  in a short discontinuous chip the chip  thickness at the start of the cut is  called the undeformed chip thickness  most milling with indexable insert  milling cutters is performed using the  climb milling mode with the insert  biting into the thickest portion of the  chip first and then thinning towards   upon exit this is the reverse of the  conventional milling mode in which the  milling cutter bites into the minimum  chip thickness at the start of the cut  and exits at the maximum chip thickness .

The milled surface results from the  combined action of cutting edges located  on the periphery and face of the cutter  the flat milled surface has no relation  to the contour of the individual teeth  except when milling a shoulder not all  face mills are used for large straight  cuts some small diameter face mills are  used to ramp into a surface then plunge  to a depth and interpolate outwards to  mill a large pocket more efficiently  than an end mill could 

There are major  variables in the design of face milling  cutter bodies which must be considered  when selecting tools these include the  cutters diameter the hand of cut the  cutter geometries including rake and  lead angles  the insert pocket design the milling  cutter pitch and the cutters mounting  method for cutting the effective  diameter is the most significant concern  the effective diameter is measured from  the highest point on an insert on one  side to the highest point on the insert  on the opposite side for proper  positioning the face milling cutters  effective diameter should be about one  and a half times the width of the cut  desired.

This allows 1/4 to 1/3 of the  cutter to overhang the edges of the  workpiece providing optimal chip  formation if the diameter of the face  milling cutter is the same as or barely  larger than the width of the workpiece  then the chips generated will be too  thin at the entry and exit of the cut  this results in a buildup of heat and  friction which will reduce tool life the  hand of the cutter is determined by  examining the cutters face while running  on a machine tool a right-hand cutter  rotates counterclockwise and a left hand  cutter rotates clockwise rake angles in  milling cutters are determined by the  cutter body and by the insert to rake  angles. 

The radial rake and the axial  rake are determined by the position of  the insert pockets in the cutter body  the radial rake is the angle measured  between the insert face and a radial  line drawn from the cutter axis to the  cutting edge hence the name radial rake  if the insert tilts toward the chip  gullet it has a positive radial rate if  the insert tilts away from the chip  gullet it has a negative radial rake the  axial rake is the angle measured between  the insert face and an axial line or  plane and it may also be positive or  negative.

The combination of axial and radial rake  angles yield three geometries of milling  cutters negative radial and axial which  offers the strongest edges but generate  the greatest cutting forces positive  radial and axial which provides the  freest cutting and negative radial  positive axial which presents a strong  edge to the work but pulls the chip up  the rake angle on the face milling  cutter inserts in conjunction with the  cutter bodies radial and axial rake  angles contributes to the cutters....

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