In the field of modern precision machining, corner radius end mills are widely used in mold manufacturing, aerospace, automotive parts and other fields due to their good anti-chipping ability and excellent cutting performance. But even high-quality milling cutters will encounter some common problems during use. This article will take you to understand the most common fault phenomena of corner radius end mills in actual use, and provide corresponding solutions to help you improve processing efficiency and tool life.

1. Tool chipping or damage

Phenomenon: Small gaps appear on the tip or blade of the tool, and in severe cases, the entire tool is scrapped.

Possible reasons:

• Processing parameters are set too aggressively (such as too large feed rate, and too high cutting speed);

• Workpiece material is too hard or has too many impurities;

• No coolant is used or lubrication is insufficient;

• Strong vibration occurs during processing.

Solution:

• Adjust cutting parameters, reduce feed and speed;

• Use tools with higher hardness or coatings (such as TiAlN, and TiSiN coatings);

• Maintain adequate cooling, it is recommended to use an internal cooling system;

• Check the equipment spindle and fixture to avoid looseness and resonance.

2. Severe tool wear

Phenomenon: The blade becomes blunt, the cutting surface is rough, and the processing efficiency decreases.

Possible reasons:

• Used for too long and not replaced in time;

• Workpiece material is highly abrasive (such as stainless steel, and titanium alloy);

• Insufficient coolant supply, heat accumulation;

• Poor tool quality, the material is not wear-resistant enough.

Solution:

• Check tool wear status regularly and replace according to plan;

• Choose carbide material with stronger wear resistance (such as HRC60 and above);

• Use efficient cooling methods, such as atomization cooling or oil mist cooling;

• Choose regular brand tools to avoid low-quality products.

3. Poor chip removal leads to tool blockage

Phenomenon: Chips accumulate in the processing area, causing the tool to overheat or even break.

Possible reasons:

• Irrational design of tool groove, insufficient chip removal space;

• The chips are too long and too hard to be removed smoothly;

• The coolant direction is wrong during processing and the chips cannot be removed.

Solution:

• Choose a corner radius end mill with a larger helix angle and wider chip groove;

• Processing path using chip breaking function;

• Adjust the direction of the coolant nozzle to enhance chip removal ability;

• Appropriately change cutting parameters to reduce chip length.

4. Poor surface roughness

Phenomenon: There are obvious knife marks, burrs or unevenness on the processed surface

Possible reasons:

• The tool is severely worn or has broken;

• The processing path is unreasonable, and the cutting angle does not match;

• The processing speed or feed is unstable;

• The machine tool has insufficient precision and there is jitter.

Solution:

• Replace a new tool to ensure the sharp edge;

• Optimize the processing path and adopt a high-precision strategy (such as equal height finishing);

• Use constant speed and constant feed processing program;

• Check the machine tool guide rails and spindle accuracy to ensure equipment stability.

5. Short tool life

Phenomenon: The tool needs to be replaced after a few uses, which is costly and inefficient.

Possible reasons:

• The tool material or coating does not match the workpiece material;

• Irrational cutting parameter setting;

• Irregular operation, such as dry cutting of hard materials, etc.

Solution:

• Select appropriate tool materials for different materials (such as ordinary carbide for HRC52 and ultra-fine particle-coated tools for HRC60+);

• Refer to the tool manufacturer's suggestions and set scientific cutting parameters;

• Standardize operation to avoid illegal use.

Summary: How can the corner radius end mill be made "less sick"?

Choose the right tool: Choose the right tool according to the processing requirements, materials, and precision.

Set reasonable parameters: Refer to the manufacturer's suggestions and do not blindly pursue high efficiency.

Maintain sufficient cooling: Cooling is like a "cooling drug" and is indispensable.

Regular inspection and maintenance: The tool is not a "disposable item", and wear management is critical.

An excellent corner radius end mill not only needs to deliver strong performance but also requires proper care and maintenance. Only by combining correct operation techniques with effective upkeep can its full potential be realized. I hope this article helps you overcome challenges during machining, enabling smoother tool usage and more efficient processing!