07-09-2014, 07:58 PM
What the low end speed of your mill in RPM, and what 3" face mill & inserts do you have? What material are you cutting?
I've got a 3" Walter F4080 43º lead angle milling cutter that take octagonal ODMT/ODHT 0605ZZN inserts. With their WKP35S grade in an F57 chipbreaker, I can run 750 to over 1200 surface feet per minute in 1018CRS, 500 to 850 in 4140 with a chipload of .004" to .006" per tooth and the inserts barely look used. Granted, that's a high-end cutter and pricey inserts, but worth every penny.
When describing inset failure modes, it's best to define that in terms of flank wear, depth of cut notching, chipping, cratering or built-up edge. I have a nice chart showing those modes, but not sure how to post a PDF file. When the failure mode is correctly identified, proper corrective action can be taken.
Flank wear - lower the cutting speed and increase feed rate
Depth of cut notching - Use a harder, more wear resistant grade or lower the cutting speed or both
Chipping - use a tougher grade with higher cobalt content
Cratering - use a harder, more wear resistant grade and/or power the feed rate
Built-up edge - lower the cutting speed and/or increase the feed rate
I can always help with carbide insert application issues as I know a few things about the subject from lots of training and reading. A little bit of experience also seems to help.
I've got a 3" Walter F4080 43º lead angle milling cutter that take octagonal ODMT/ODHT 0605ZZN inserts. With their WKP35S grade in an F57 chipbreaker, I can run 750 to over 1200 surface feet per minute in 1018CRS, 500 to 850 in 4140 with a chipload of .004" to .006" per tooth and the inserts barely look used. Granted, that's a high-end cutter and pricey inserts, but worth every penny.
When describing inset failure modes, it's best to define that in terms of flank wear, depth of cut notching, chipping, cratering or built-up edge. I have a nice chart showing those modes, but not sure how to post a PDF file. When the failure mode is correctly identified, proper corrective action can be taken.
Flank wear - lower the cutting speed and increase feed rate
Depth of cut notching - Use a harder, more wear resistant grade or lower the cutting speed or both
Chipping - use a tougher grade with higher cobalt content
Cratering - use a harder, more wear resistant grade and/or power the feed rate
Built-up edge - lower the cutting speed and/or increase the feed rate
I can always help with carbide insert application issues as I know a few things about the subject from lots of training and reading. A little bit of experience also seems to help.