MITSUBISHI MATERIALS CORPORATION
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FUNCTION OF TOOL FEATURES FOR FACE MILLING

FINISHED SURFACE
FINISHED SURFACE
Cutting Edge Run-out and Accuracy in Face Milling
Cutting Edge Run-out and Accuracy in Face Milling

Cutting edge run-out accuracy of indexable inserts on the cutter body greatly affects the surface finish and tool life.
Three Cutting Resistance Forces in Milling





Face Milling Run-out Accuracy
Minor Cutting Edge ≤.0012inch
Peripheral Cutting Edge ≤ .002inch

Improve Finished Surface Roughness


Sub Cutting Edge Run-out and Finished Surface
Sub Cutting Edge Run-out and Finished Surface

 Since Mitsubishi Materials' normal sub cutting edge width is .055mm, and the sub cutting edges are set parallel to the face of a milling cutter, theoretically the finished surface accuracy should be maintained even if run-out accuracy is low.
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  • Replace one or two normal inserts with wiper inserts.
  • Wiper inserts are set to protrude by .0012 ― .004 inch from the standard inserts.
Actual Problems
  • Cutting edge run-out.
  • Sub cutting edge inclination.
  • Milling cutter body accuracy.
  • Spare parts accuracy.
  • Welding, vibration, chattering.
Countermeasure

Wiper Insert
* Machine a surface that has already been machined by normal insert in order to produce smooth finished surface.

How to Set a Wiper Insert
One Corner Type
Two Corner Type
Two Corner Type
(a)One Corner Type
Replace normal insert.
(b)Two Corner Type
 Replace normal insert.
(c)Two Corner Type
Use supporter for
wiper insert.
  • Sub cutting edge length has to be longer than the feed per revolution.
    *Too long sub cutting edge causes chattering.
  • When the cutter diameter is large and feed per revolution is longer than the sub cutting edge of the wiper insert, use two or three wiper inserts.
  • When using more than 1 wiper inserts, eliminate run-out of wiper inserts.
  • Use a high hardness grade (high wear resistance) for wiper inserts.