As a planar material removal technology, face milling is worth choosing in terms of its ability to process workpieces. Its working effect is value for money in the eyes of manufacturers.
What is face milling? It is a remarkable craft used by machinists to remove surface irregularities and improve appearance during milling. It uses a multi-edged tool as the workpiece and works in translation and rotation.
This blog post will give you a unique perspective on some of the benefits and types of operations of this milling technology. Of course, wanting to demonstrate face-milling technology doesn’t stop there.
It also gives you an idea of the type of tool a mechanic chooses and the circumstances in which it is suitable. Finally, this blog post also describes how this technology differs from other processes.
What Are The Advantages Of Face Milling?
Removal Efficiency
The knives for this flat-cutting technology have sharp cutting edges and speed. It can remove flawed and flawed workpiece surfaces with fast cutting speed.
Accurate Plane
Cutting by machinist design, this technique allows for different types of surface finish. It underscores the slippy look and feel of high-feed process execution.
Multiple Applications
This planar removal process has no restrictions on the amount of material removed and the type of workpiece. This smooth-cutting technology handles it regardless of the material type such as metal, plastic, or wood.
What Types Of Face Milling Are There?
Cutting tasks under different conditions are supported by different milling operations. The following blog posts demonstrate the different types of action types.
General Face Milling
For ordinary processing materials and requirements, the working capacity of general milling is sufficient. It produces the desired surface for the workpiece at a working angle of 45 degrees.
High Feed Milling
It is a flat-face operation type with an entering angle of 10°. That means it is more efficient than general milling operations at removing unnecessary material.
Heavy Duty Face Milling
This heavy-duty milling operation is capable of large and robust material removal jobs. It can cut both depth and width to handle overstocked parts.
Finishing With Wiper Inserts
It is a milling operation that achieves a finishing finish on the surface of a material. Its knives differ in that they have smaller blades. Therefore, its finishing surface treatment ability is superior to other operation l types.
The type of milling operation should be reasonably screened according to the processing conditions and difficulty of the project.But the types have different applicable conditions, and the mechanic will analyze the details and characteristics of each operation. If you have difficulties with face milling, you are welcome to contact Tirapid technical experts.
What Are The Operation Skills Of Face Milling?
The so-called milling skills are a valuable experience summed up by Tirapid experts for many years in milling operations.The following content can get some help and answer your doubts.
1. The displacement of the workpiece may cause errors in the final cutting effect. Typically, a mechanic will use a stationary tool, such as a clamp or vise. This method can guarantee the smooth running of the workpiece on the machine tool.
2. Ignore the hindrance that debris left on the machine tool can cause to the operation of the machine tool. Chip evacuation issues can affect a milling cutter’s ability to perform standard milling operations. Typically, machinists use cooling oil to keep the cut smooth and smooth.
3. In the preparation work, pay attention to the setting operation of the face milling equipment. Because the operation of this step is related to the effect of the whole milling operation part. The parameters set include cutting speed, feed rate, and cutting depth.
4. The planning plan can predict the risk of operation and conduct a detailed analysis of the operation process.The machinist will start planning with tool type, material, and cutting design. A good milling program can lay the foundation for results.
5. Real-time monitoring and proofreading of parts are required. Machinists monitor to ensure that workpieces are milling as planned. At the same time, monitor whether the tool is in good condition to ensure timely replacement. Guarantee the quality and accuracy of the milling operation of the workpiece during the monitoring operation.
6. Pay attention to the steps and processes of standardized operations during milling operations. At the same time, operators should be equipped with protective equipment to ensure that there will be no safety accidents during face milling operations.
What Are The Tools For Face Milling?
Face milling processes different workpieces with different styles of tools. The following will introduce you to some of the milling cutters that machinists will use in the face milling technology center:
Ordinary Face Mills
It is a general-purpose type of ordinary face mill with a big cutting-diameter style design. Machinists typically use these types of knives for heavy cutting. It has high material removal rate capabilities and performs well in roughing and semi-finishing operations.
Shell Mills
Shell milling cutters are generous in tool diameter and have regular cutting teeth. It is easy to use and capable of high removal rate cutting operations for material surfaces. Shell Mills are available in different sizes and sizes, so they are highly adaptable.
Flying Knife
A flying knife is a style of knife with a single cutting edge. It solves large area removal tasks of end faces, curved surfaces, and squares with CNC milling machines. Because the structure style of the flying cutter is relatively simple, its cutting cost is lower than other milling cutters.
Indexable Face Mills
It is a tool with cutting-edge geometry and a chip breaker pattern. From the machinist’s point of view, using an indexable face mill is cost-effective. It can replace designated damaged inserts, reducing the time of the entire milling operation.
Three-Sided Milling Cutter
A three-side milling cutter is a tool characterized by three cutting edges. Due to this tool structure, it has high rigidity. It has no difficulty in handling different grades of metal materials and diverse types of operations.
High-Speed Steel (HSS) Face Mills
The material of this knife is metal high-speed steel. Therefore, the tool is highly impact resistant and easy to sharpen.It handles milling operations capable of achieving high surface finishes.
Carbide Face Mills
Carbide Face Mills offer advantages in high-temperature, high-speed surface milling operations.It can meet the challenges of milling of high-hardness metal alloys. When the project is faced with high surface finish requirements and does not care about the budget, a carbide face milling cutter is a good option.
When faced with the problem of choosing the best surface milling tool, it is necessary to refer to various criteria. That includes conditions such as tool style, tool stiffness, and cutting ability. If you have doubts about tool selection can contact Tirapid online to answer your questions.
What Are The Tips For Using Knives?
The tool can improve the efficiency of the operation through some skills when face-milling the workpiece. When Tirapid milling engineers surface milling, there are the following skills and precautions:
1. When using cemented carbide flat milling cutters, pay attention to the problem that the blade is prone to breakage. When flat milling, it is necessary to pay attention to the operating parameters of the tool. To ensure that the cutting of the cemented carbide flat milling cutter will not break due to impact.
2. HSS flat milling cutters have different processing requirements for diverse materials. Milling brass, for example, requires low cutting speeds and feeds. In this case, low speed and feed can help the material to evacuate chips effectively.
3. face milling operations require the proper addition of sufficient coolant. Ensure that the waste during flat milling does not affect the face-milled parts.
4. The selection of tools should refer to different conditions. The best choice is a tool that can match the cutting requirements and is economical. In addition, creating a groove or edge of a customized style also requires the selection of specialized props.
5. Tool inspection before milling operation is a routine item in technical machining. Replace defective or defective knives. Reduce tool errors in flat milling operations by inspection.
6. Simulate the flat milling path of the cutter in advance. Reduce unnecessary material loss and milling costs by simulating operations.
What Is The Difference Between Face Milling, End Milling And Peripheral Milling?
Face milling, peripheral milling, and end milling are milling processes that differ in many ways. So read this blog post to tell the difference between these three milling modes:
Cutting Method
Face milling is to start processing on the surface of the machined parts, and it performs translational cutting work on parts or components. Generally speaking, its translation operation makes the workpiece create a smooth and exquisite surface.
End milling focuses on the side of the workpiece in the cutting method. It is the detailed construction of grooves, threads, and contours for part machining in a manner that engages the cutting components.
Peripheral milling takes cutting the peripheral part of the workpiece as the main processing method.It has the advantage of creating grooves that have the effect of merging several pieces.
Blade Style
Face milling uses disc milling cutters with multiple cutting edges. And the machinist cutting edge is easy to assemble and replace when broken. Additionally, it increases efficiency when removing large areas.
The tools used in end milling are usually fluted and cylindrical-style milling cutters. The mounting position of the cutting edge of the end mill is on the periphery of the end face. End milling tools provide versatile operations specifically for feature-creating machining.
Peripheral milling cutters have a peripheral tooth design. The tooth design for perimeter milling is able to handle sharp workpiece edges. It is advantageous to design the external thread and the external contour at the machined edge.
Cutting Direction
Face milling is the working angle at which the tool is perpendicular to the workpiece. The surface of the workpiece is milled using rotary cutting.
End milling is the cutting of parallel surfaces by the end mill cutter and the machined part.
Perimeter milling is a rotary cutting direction similar to milling, but the cutting position is around the workpiece.
The above is the difference between the two different processes. This blog post provides directions for manufacturers to choose from the cutting method, tool, and working orientation. The comparison can help the workpiece choose the most effective technology.
What Is The Process Of Face Milling?
By familiarizing yourself with the operation process of flat milling technology, you can better understand the charm of this process:
Fixed Workpiece
The fixture is fixed on the face milled part so that the angle and precision of the cut are accurate.
Select Milling Cutter
Then choose the right and cost-effective cutting tool and flat milling cutter type for different milling applications.
Set-Up
Secondly, accurately set the cutting speed or feed per tooth of the lathe milling to ensure that the face milling accuracy is up to standard.
Chip Removal
Carry out waste removal during the operation, and properly add coolant to the machine tool to assist.
Examine
Finally, check whether the face milling products meet the production standards in an all-around way to avoid unnecessary losses due to shipment.
Advantages of Tirapid Face Milling Services
The service capability of Tirapid in the face milling sector is well-known to all at home and abroad. You don’t have to worry about machine vibration or chip evacuation that may occur during milling operations. Tirapid experts will solve your milling challenges for the first time. In addition, Tirapid has always been known for serving customers with fair and favorable prices. By sending your custom diagram online, a Tirapid expert will quote you within 3 hours. Through our efficient milling operation, the delivery can be completed for you within 3 days at the earliest.
Summarize
Face milling offers unique advantages when it comes to removing surface material and creating details. This technique brings many challenges in detail, and this operation strategy can provide you with ideas for solving them. Inspired by this face-milling blog post, optimizing the details of the process can go a long way.
There are many operations across industries that require the creation of surface features and details, and surface milling has ample operational advantages in this regard. Not only that, it is cost-effective in the processing of flat surfaces. You can contact Tirapid’s senior milling experts online to give you the most effective advice.
FAQs
1. What is the speed of cutting in a face mill?
Under normal circumstances, its cutting speed can reach 100m/min. In addition, Tirapid experts recommend calculating cutting speed by formula to get accurate data. The cutting speed formula is: cutting speed (SFM or m/min) = (π×tool diameter×spindle speed)/12. But we need to know that the cutting speed of the milling cutter will vary with different tools.
2. What angle face milling will give the best results?
In surface-cutting technology, the main deflection angle of 45°～90° is the most widely used range. Adjust the angle of service according to different milling conditions and application requirements. Tirapid experts recommend that you consult a professional mechanic for the best operation of your project.
3. How much depth of cut can a face milling cutter achieve?
It can achieve a cutting depth of 10-20mm or more. In addition, technical conditions will also lead to the impact of the depth of the cut. For example, the depth of cut of a milling cutter is affected by the diameter of the tool, which is generally in the range of 0.5 to 2 times the diameter of the tool. Therefore, the final depth of the cut setting needs to refer to different data and guideline recommendations.
4. Which materials can be effectively face-milled?
First, it is available in hundreds of materials, including metallic steel, copper, cast iron aluminum, brass, steel, stainless steel, iron, die-cast aluminum, and more. Plastics include PEEK, Nylon, Acrylic, PVC, POM, PEEK, ABS, and more. Every material behaves differently, and the conditions for a flush cut vary from material to material. The prerequisites for effective surface milling require a combination of various control factors. Tirapid experts suggest that the selection of materials should also refer to miscellaneous recommendations.
5. What is the machining time for face milling?
Usually, it takes a few seconds or a few hours. The processing time of milling will affect the time length change in terms of complexity, machine tool capacity, and equipment settings. Tirapid recommends that you optimize the surface milling process from the above conditions. It can achieve the effect of shortening the processing time.
6. What types of surface finishes can be achieved with face milling?
Typically, this type of milling surface finish can include accurate, textured, or rough surfaces. The surface roughness processed by Tirapid can reach Ra0.6um, and the conventional surface is Ra1.6~3.2um. The machinist can adjust the plane milling parameters according to your requirements to achieve different types of surface finish. If you have questions about the milled surface, Tirapid can advise you on the appropriate surface finish.
7. What are the factors that affect the service life of milling cutters?
Through the research and analysis of milling cutters, the factors affecting the life of milling cutters cover many aspects. It includes the speed and feed rate of the milling cutter operation and the depth of cut to the workpiece. In addition, additional factors such as milling cutter storage environment, maintenance method, and tool coating may affect the life. Tirapid experts suggest starting from the above factors to extend the service life to the greatest extent.