Face milling cutters are also called disc milling cutters. They are used to process planes on vertical milling machines, face milling machines or gantry milling machines. There are teeth on the end and circumference, as well as coarse and fine teeth. Its structure has three types: integral type, insert type and indexable type.
Face milling cutters are divided into two categories. The first category is to fix the cemented carbide blade on the cutter teeth by brazing, and then install the cutter teeth on the cutter body. This is called the inlaid tooth face milling cutter;
The second type is to install carbide inserts directly on the cutter body of the milling cutter, and then fix it with screws. This is called indexable machine clamp milling cutter.
The face milling cutter has two rake angles, axial rake angle and radial rake angle. The direction of the two rake angles is selected according to the material and cutting conditions of the processed object, namely positive +, negative-or zero.
To calibrate carbide inserts, there are two parts, inspection and adjustment. Generally, there are several methods for inspection:
For the on-machine tool setting method, directly on the machine tool, use a tool setting instrument besides the machine, or suck a dial indicator at a suitable position on the worktable, and the end face of the meter probe should be flat. Detect the radial and axial runout of the blade edge respectively. This method is more used in some small and medium-sized machinery processing enterprises.
Blade setting method outside the machine A: the radial and axial directions of the cutting edge are simultaneously detected on the tool setter outside the machine. This is the method used by most mechanical processing plants now.
Blade setting method outside the machine B: a marble plate is specially prepared in the tool room, and there is a bracket to clamp the dial gauge; a dial gauge can also be clamped on a table frame to check the axial runout. This is more used in some large mechanical processing plants. To measure radial runout, a fixed mandrel is needed.
There are two types of face milling cutters: non-heavy grinding blades and welding blade, which are divided into two categories: adjustable and non-adjustable. For adjustable milling cutters:
Only axially adjustable. Used for occasions with more general requirements. Such as coarse and fine composite milling cutters.
Adjustable in two directions, axial and radial. Used in demanding processing occasions. Such as some demanding precision milling cutters.
Three parameters of axial, radial and angle are adjustable. Used in demanding occasions. Such as flatness requirements, surface roughness requirements, angle requirements, etc.
The adjustment of this type of milling cutter is relatively simple, as long as the corresponding adjustment mechanism is fine-tuned when the above-mentioned detection method detects.
For milling cutter heads without adjustment mechanism, carbide inserts are generally clamped into two types: platen insert clamping and center screw clamping. The correction methods are:
The principle is to ensure the best axial runout. The radial runout is required to be within 0.05 mm.
The particularly high and particularly low blades are taken out and used together, generally controlled at about 0.05 mm.
Place a pre-cut thin gasket under the lower blade, the thickness is about 0.02~0.03 mm, and it is modified with a feeler gauge. Make the axial runout within 0.01 mm. The rough machining cutter head can relax the requirements. The rough and fine composite cutter head are according to the manufacturer’s standard. Generally, the height of the finishing blade is about 0.05 mm.
When the individual cutter body is particularly high, it needs to be corrected manually by the tool fitter. After the face milling cutter head and the tool holder are installed on the spindle of the machine tool, there will be accumulated errors. If the requirements are high, it needs to be recalibrated on the machine tool. The high-speed cutting milling cutter must also be tested for dynamic balance.