Issues and solutions when using an end mill

Damaged blades
  • Fast transfer speed, excessive amount of slotting
  • Excessive protrusion of tool
  • Inadequate stiffness of tool
  • poor fixation of item
  • Poor fixation of item
  • Reduce transfer speed
  • Reduce amount of slotting
  • Reduce amount of protrusion
  • Use minimum blade length
  • Increase fixed stiffness
  • Increase fixed stiffness
Vibration occurred during cutting
  • Excessive primary outer relief angle
  • Excessive protrusion of tool
  • Improper cutting conditions
  • Reduce primary outer relief angle
  • Reduce the amount of protrusion
  • Adjust cutting and transfer speeds
Reduced cutting performance
  • Use unsuitable end mill
  • Low outer inclination angle
  • Rapid wear of cutting blades
  • Use an end mill suitable for items to be cut
  • Increase outer inclination angle
  • Perform early regrind
Sudden occurrence of wear
  • Excessive cutting speed
  • Unsuitable outer inclination angle
  • Upward cutting operation
  • Reduce cutting speed, modify outer inclination angle
  • Consider downward cutting operation
Poor chip discharge
  • Small space for chip discharge
  • Excessive wear on blades
  • Excessive amount of slotting
  • Low injection pressure or amount of cutting oil
  • Reduce transfer speed and use an end mill with small number of blades
  • Perform early regrind
  • Reduce amount of slotting
  • Increase injection pressure and amount
Poor surface roughness
  • Fast transfer speed
  • Rapid wear of cutting blades
  • Excessive amount of slotting
  • Low cutting speed
  • Reduce transfer speed
  • Perform early regrind
  • Reduce amount of slotting
  • Increase cutting speed
Damaged during cutting
  • Fast transfer speed
  • Excessive protrusion of tool
  • Significant damage of cutting blades
  • Excessive amount of slotting
  • Reduce transfer speed
  • Reduce amount of protrusion
  • Perform early regrind
  • Reduce amount of slotting
Poor processed dimensions
  • Small number of blades
  • Excessive cutting conditions
  • Use of long blades
  • Poor accuracy of machine or chuck
  • Use an end mill with a greater number of blades
  • Adjust cutting conditions, replace
  • Use short blades, repair or replace machine or chuck