Milling cutters are expensive - a 100mm diameter face milling cutter body can cost in excess of $600 - so care should be taken in choosing one that is truly suitable for the specific machining needs.
First, when choosing a milling cutter, consider the number of teeth it has. For example, a rough cutter with a diameter of 100mm has only 6 teeth, whereas a close cutter with a diameter of 100mm can have 8 teeth. The size of the tooth pitch will determine the number of teeth involved in milling at the same time, affecting the smoothness of cutting and the requirements of the machine cutting rate. Each milling cutter manufacturer has its own series of rough and close toothed face milling cutters.
When rough milling with heavy loads, excessive cutting forces can cause chatter in less rigid machines. This chatter can lead to chipping of the carbide inserts, which can shorten tool life. Selecting roughing cutters reduces the power requirement of the machine. Therefore, when the spindle hole specification is small (such as R-8, 30 #, 40 # taper hole), you can use the coarse tooth milling cutter effective milling processing.
The roughing cutter is mostly used for roughing because it has a large chipformer. If the chipformer is not large enough, it will cause difficulty in rolling chips or increased friction between chips and cutter body and workpiece. At the same feed rate, the cutting load per tooth of roughing milling cutter is larger than that of close-tooth milling cutter.
Precision milling depth of cut is shallow, generally 0.25 ~ 0.64mm, the cutting load per tooth is small (about 0.05 ~ 0.15mm), the power required is not large, you can choose a dense tooth milling cutter, and you can choose a larger feed. Because the metal removal rate in the fine milling is always limited, the dense tooth milling cutter chip slot is also small.
For spindles with large tapered holes and good rigidity, rough milling can also be carried out with close-grooved milling cutters. Due to the dense tooth milling cutter at the same time more teeth involved in cutting, when using a larger depth of cut (1.27 ~ 5mm), pay attention to the machine tool power and rigidity is sufficient, whether the milling cutter chipformer groove is large enough. Chip removal needs to be verified experimentally, if there is a problem with chip removal, the cutting amount should be adjusted in time.
