This document discusses common milling troubles and how to avoid them. It identifies the main issues as vibration caused by weak fixtures, burr formation especially in titanium, chip jamming in long materials, insufficient machine power, poor surface finish, and premature tool wear. The solutions include adjusting cutting speed, depth, feed rate, pitch, or choosing a different insert to resolve the specific issues.

1. 6milling
troubles
(and how to avoid them)
Vibration
Vibration issues can happen from weak
fixtures or work-piece or simply by using
the wrong cutting data or insert. The
solution may be as simple as reducing
the cutting speed or changing the cutting
depth.
Burr formation
Problematic with full slotting and pocketing
in titanium but also when milling deep
cavities and pockets on vertical machines.
Troubles include fractures to the cutting
edge, chip jamming and more.
Chip jamming
Chip jamming is a common obstacle when
full slotting, especially in long-chipping
materials, and causes insert corner
damage, edge chipping, breakage and
re-cutting of chips.
Machine power
Power requirements vary depending on
amount of metal removal, average chip
thickness and cutting geometry. It could
require changing the pitch on your milling
cutter or changing your depth of cut.
Poor surface finish
Surface finish can be of critical importance.
Don’t risk scrapping components. If you
are dissatisfied with your surface finish, you
may need to decrease the feed rate per
revolution or try a Wiper insert.
Tool wear
Premature tool wear can be caused by a
feed rate that is too low to cutting speed
that is high. See how to avoid flank, crater,
and notch wear, thermal cracking and
built-up edge to get more from your inserts.
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