Using a corner radius mill to cut shapes and edges can be an efficient task, but only if you know the right parameters involved. We’ll cover everything from important cutting variables, to different tool types, to the range of materials that can be successfully milled with a corner radius mill.
Determining the Right Corner Radius.
The corner radius of the mill is an important factor in determining its cutting capabilities. Generally, you want to choose a tool with a corner radius that is slightly greater than the desired final corner radius of the part. This allows for safer and more precise cutting, as well as minimizing potential tear-out or breakage during machining. Additionally, you should consider the sharpness of corners on your workpieces to ensure that they are not too sharp for the selected cutter.
Setting Cutting Pitch and Rake Angles Appropriately.
The cutting pitch is the angle of which a single flute contacts the material being machined. The rake angle is the inclination of cutting edges relative to the workpiece surface. These angles should be optimized based on material and design, as incorrect settings may cause excessive vibrations or damage to both tool and workpiece. Selecting appropriate settings for these parameters will result in better finishes with extended tool life. Additionally, high rake angles should be used with harder materials while low rake angles work better when soft materials are machined.
Establishing the Most Effective Feed Rate for Toolpaths.
It’s important to establish the most effective feed rate for your toolpaths in order to make sure that each operation runs smoothly and efficiently. The feed rate must be set at an appropriate value so that the chip load remains within range and at a low enough level to prevent overload on the cutting tool. Setting a correctly balanced feed rate will also ensure maximum engagement of the corner radius mill which can result in improved performance, better surface quality, and a longer lifespan for the tool.
Selecting the Right End Mill Size and Material for Your Workpiece
When it comes to selecting the right end mill size and material for your workpieces, certain factors should be taken into consideration. First off, the size of your corner radius mill should accommodate the materials being machined in order to provide maximum engagement. In addition, make sure that the end mill you select has adequate flute depth for the depth of cut desired, even if multiple passes are necessary per cycle. That way, you can better achieve optimum results with your cutting tools.
Choosing the Optimal number of Flutes for Each Modeled Feature.
When choosing the optimal number of flutes for each modeled feature, always take into account how much material can be removed with a single pass. The fewer flutes your corner radius mill has, the larger engagement it will provide and reduce chipping/scraping on exit. However, too few flutes may cause chip-packing issues that lead to breaks and poor finishes. On the other hand, more flutes will produce smoother finishes since they are capable of removing material faster and more consistently while maximizing chip clearance away from the cutting edge.
