6 Ways to Optimize High-Feed Milling

Where drilling would draw too much power on low-power machines, this high-feed mill offers the option of instead creating holes by helical ramping. Photo credit, all images: Seco Tools

You can find more information on our web, so please take a look.

High-feed milling focuses on removing as much material as possible in the shortest amount of time. This process has been established for quite a while and can lead to more profitable business opportunities. However, some manufacturers have moved away from this method due to perceived reliability issues. It is true that if implemented incorrectly, high-feed milling can produce undesirable results.

For those willing to embrace it, the advantages of high-feed milling can greatly surpass potential drawbacks. This technique offers remarkable productivity, achieving nearly three times the metal removal rate of traditional methods while also extending tool life. However, to ensure successful high-feed milling executions, several key considerations must be addressed.

Machine Tools

Sturdy, capable machine tools are essential since high-feed cutters operate at increased speeds, requiring both the machine and control systems to keep pace. Investing in new machinery can significantly enhance your high-feed milling capabilities. Although it is feasible to apply updated high-feed mills to older machines, they perform best with larger cutters due to less accelerated feeds and speeds.

Utilizing high-feed cutters that incorporate trigon-style inserts allows for the lowest possible lead angle compared to round or square inserts, directing cutting forces axially. This enhances stability and reduces strain on the machine.

Inserts

Trigon-style inserts are advantageous due to their low lead angles, which create thinner chips thus necessitating higher feed rates for maintaining the right chip thickness in accordance with the insert geometry. This lower lead design also manages cutting forces in the axial direction, contributing to greater stability and less pressure on the machine. Conversely, higher lead angles generate thicker chips, demanding less feed adjustment but producing more radial force, potentially causing vibrations and stress on spindle bearings.

Insert Grade

Ensure to select the appropriate insert grade for your application, as premature tool failure is detrimental, especially during unattended operations. Choosing the right grade tailored to the material involved can enhance tool performance reliability, resulting in fewer replacements, reduced reject rates, and less rework.

High-feed mills excel in plunge milling scenarios as they are designed for minimal resistance and effective chip removal.

Machining Application

Not all machining techniques are equal. While long overhangs in high-feed mills can be beneficial, it's crucial to remember that they should not be operated at speeds significantly higher than tools with shorter overhangs unless specialized vibration dampening toolholders are used or cutting speeds are decreased. Exceeding speed limits with tools that have long overhangs can lead to increased vibrations, which may cause insert chipping and early tool failure.

You will receive efficient and thoughtful service from Guangzhou Ruiyi Technology Co., Ltd..

Programming

Optimize the cutter path with appropriate programming to prevent placing excessive strain on your cutting tool. When navigating corners in a mold, abrupt direction changes without smooth transitions can be detrimental to the tool as it creates a significant angle of engagement. A good practice is to program an arc at least 50% larger than the cutter diameter; for a 2.0" cutter, plan for a 3" arc. This approach will decrease the angle of engagement at pocket corners and help avoid overloading the cutter. It's also essential for machine tools to effectively calculate arcs; otherwise, unpredictable tool paths may occur.

Engaged Tools

Keep your high-feed mills as engaged as possible across the full diameter or at least less than half the insert width. Maximizing engagement is crucial because it aligns cutting forces axially toward the spindle, promoting balance. If the same tool is only employed to 50% or 60% of the diameter, it can lead to push and increased vibrations due to an unbalanced cut.

For more information, please visit High Feed Milling Inserts.