Introduction
In modern manufacturing, milling technology is particularly important. Corn milling cutter and chip splitter insert are key cutting tools and are widely used in various processing fields. This article will explore the performance characteristics, application fields, usage requirements and installation techniques of these two tools to help users improve processing efficiency and surface quality.
1. Performance characteristics and application of corn milling cutter
The corn milling cutter is a high-performance and cost-effective cutting tool. With its strong blade and large helix angle, it can ensure sufficient contact teeth and a smooth cutting effect, thereby providing a smooth cutting process and excellent surface roughness.
1.1 Slot milling application
In slot milling applications, it is recommended to use conventional tooth profiles to provide larger chip removal space and higher stability.
- When the tool diameter (DC) is ≤40mm, the maximum cutting depth is 50% of the tool diameter (APMXS=0.5xDC);
- When the tool diameter (DC) is >50mm, the maximum cutting depth is 25% of the tool diameter (APMXS=0.25xDC);
- When processing grooves, it is recommended to use power milling, the maximum cutting depth is 70% of the tool diameter, and the groove width (ae) can be set to 10% of the tool diameter (ae=10%xDC).
1.2 Contour milling/side milling application
During the contour milling or side milling process, a close-pitch tool is recommended.
- When using the maximum cutting depth of the tool, it is recommended that the maximum radial cutting depth (ae) is less than or equal to 30% of the tool diameter (ae/DC≤30%).
1.3 Requirements for the use of corn milling cutters
- The processing system must be stable and the machine tool spindle must be strong;
- The machine tool power and low-speed torque must be large;
- The workpiece must be firmly clamped to ensure machining accuracy;
- There must be good chip removal conditions;
- The tool holder must be reliable and firm;
- It is recommended for side milling and dynamic milling is recommended for groove processing.
2. The role and advantages of chip splitter inserts
The chip splitter insert can effectively improve the chip-breaking problem during the machining process by cutting the chips into smaller pieces, reducing the cutting force, and ensuring the smoothness of the machining. Specific advantages include:
- Reduce cutting force: Smaller chips require less energy, reducing cutting force and ensuring a lighter and smoother machining process;
- Improve chip removal: Small chips are easier to discharge, avoiding chip accumulation and secondary cutting, and reducing machining waste;
- Improve machining stability: The optimized chip control system helps to improve machining stability and reduce tool wear.
3. Tips for installing and using chip splitter inserts
To ensure optimal performance, chip splitter inserts need to be installed and used in the correct way:
3.1 Tool selection
- It is recommended to use a milling cutter with an even number of teeth (e.g., a cutter head with 2, 4, 6, or 8 teeth).
- Edge I should have 3 chip splitters, while Edge II should have 2 chip splitters.
- Install the insert according to the installation diagram, ensuring that edges I and II are installed alternately.
3.2 Problems with using odd-numbered cutters
When using a milling cutter with an odd number of teeth (e.g., a cutter head with 3, 5, 7, or 9 teeth), since it is not possible to install edges I and II alternately, the last tooth can only share the same chip splitter type as the previous tooth (or the next tooth).
- This may result in residual raised lines on the side wall of the workpiece caused by the chip splitter groove, which can be up to 0.3 mm higher than the processing of an even-numbered cutter head.
- When the feed per tooth (Fz) is greater than 0.3mm, the radial cutting depth will exceed the depth of the chip splitter, and the insert will cut with the full edge, resulting in the failure of the chip splitting function.
Conclusion
Corn milling cutters and chip splitter inserts play an important role in modern manufacturing, which can significantly improve processing efficiency and surface quality. Choosing the right tool and the correct installation method are essential to ensure processing stability and extend tool life. By following the above usage recommendations and installation tips, you can maximize the performance of the tool and optimize the production process.
