Page 1032 - Tungaloy Catalog

Technical Reference
Milling Tools
Trouble shooting in face milling

Trouble Possible causes Countermeasures
• Improper insert grade selection • P30 (Cemented carbide) / Cermet, coated grade (For steels)
Rapid wear of (Insufficient wear resistance) • K10 (Cemented carbide) / Coated grade (For cast irons)
cutting edge • Excessive cutting speed • Select cutting speed suited for work material and insert grade
• Inadequate feed • Use standard cutting condition in catalog as guide
• Improper Insert grade selection (Insufficient toughness) • Cermet / P30 (For steels), K10 / K20 (For cast irons)
• Cutting hard material and • Decrease cutting speed
unfavorable surface condition • Use cutter with strong cutting edge
Rapid chipping of
cutting edge • Excessive feed • Proper selection of feed conditions, using recommended cutting conditions in catalog as guide
• Excessive pressure applied on cutting edge • Proper selection of engaging angle
• Machining superalloys • Use a negative-positive type cutter with large corner angle
(Examples: T/EAW13, T/EME4400, etc.)
• Cracking due to thermal shock • Select insert grade of stronger thermal shock resistance such as T3130
• Decrease cutting speed
• Continuous use of excessively worn insert • Shorten replacement standard time of insert
• Cutting hard material • Use cutter with stronger cutting edge such as T/ERD6000
• Use cutter of larger corner angle such as
T/EAW13, T/EME4400, etc.
Fracturing
• Obstruction to chip flow • Use cutter with better chip expulsion such as T/EAW13, etc.
• Recutting of chips after chip welding • Select insert grades difficult for chips to adhere
Cemented carbides / cermets, coated grades
• Use air blow
• Excessively slow cutting, too fine feed • Select cutting speed and feed optimized for insert grade and
work material
• Cutting soft material such as aluminum, copper, mild steel • Use cutter with large rake angle such as T/EAW13
Excessive chip
welding or build-up • Cutting stainless steel • P30 / coated grades (AH140, AH120)
on cutting edge • Use of cutter with negative rake • Use cutter with large rake angle such as T/EAW13, T/EME4400,
or too small rake angle T/EPW13 or T/ESE4000
• Effect of built-up edge • Increase cutting speed
• Appropriate cutting depth (finish allowance)
• Change insert grade For steels: P / coated / cermet
For cast irons: K / coated
• Effect of face cutting edge run out • Proper installation of inserts
Rough finish • Use insert of high dimensional accuracy
Technical Reference • Continuous use of excessively worn insert • Shorten replacement standard time of insert

• Cleaning of insert pocket
• Feed per revolution to be set within flatland width
• Remarkable feed marks
• Use wiper insert type cutter such as T/EAW13

• Use cutter exclusively for finishing such as NMS and S/EFP4000

• Unstable clamping of workpiece
• Use cutter with large rake angle and small corner angle such as
• Cutting of welded construction of
T/EPW13 or T/ESE4000
thin steel plate • Check clamping method of workpiece
Chattering
14 • Excessive cutting condition • Re-examine allowable chip removal rate according to motor HP
• Face milling of narrow width workpiece • Use cutter of small cutter diameter and with many teeth
• Too many simultaneous cutting teeth engagement • Reduce No. of teeth or use irregular pitch cutter

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