REGO-FIX Main Catalogue ENGLISH

Milling strategies
Which milling strategy is the most suitable for my application? HSC, HPC
or trochoidal milling? Am I focusing on a high chip removal rate or a
perfectly finished surface? Choosing the most efficient method and
reaching the maximum performance is the key to successful machining.
Depending on the type of machine, lot size, clamping equipment
and many other factors, the fastest strategy might not
be the most efficient. Sometimes, a conventional approach
is faster for smaller quantities than a perfectly optimized
CAM-program following the latest development.
Machines – 3, 5 or 5-axis simultaneous 3-axis and 5-axis are
essentially different types of milling machines. The definition
stands for the number of axles the machine can move, on
a 3-axis machine it is usually X, Y and Z. If you add a rotary
head and table to the machine, often called A- and C-axis, it
becomes a 5-axis machine. It allows you to machine up to 5
sides of a workpiece in a single clamping as well as applications
at any angle necessary. A 5-axis simultaneous machine
is able to move all of its axles at the same time and is used
for workpieces with complex 3D contours.
Down-milling In almost any application, down milling is the
preferred method and base of modern milling strategies.
Following the “thick to thin” rule, the feed is in the same
direction as the rotation of the cutting tool. The maximum
chip thickness is reached at the start of the cut and slowly
decreases until the end of the cut. Results are better surface
quality, longer tool life and less burr formation.
Up-milling If the cutting tool is fed in the opposite direction of
the cutting tool rotation, an up-milling strategy is applied. The
slowly increasing chip thickness causes high temperatures
and a burnishing or rubbing effect due to friction, resulting
in a reduced tool life. Different than in down-milling, the tool
gets pulled towards the workpiece which was a welcoming
effect in earlier years of milling machines. As the precision
of spindles and guides couldn’t reach modern standards, it
helped stabilizing the milling process. In today’s machining,
up milling is used in workpieces with hardened, abrasive or
forged surfaces, allowing the tool to start the cut in softer
material to increase tool life.
Roughing The roughing process is mostly used at the beginning
of a workpiece. Aiming at removing a large amount of
material in the fastest and most process-safe way and get
as close as possible to the final shape. Surface quality and
dimensional accuracy are secondary requirements.
Finishing Following the roughing process, finishing operations
are used to achieve the required specifications regarding
dimensional and geometrical accuracy, surface quality,
deburring and an optimal preparation for following processes
such as grinding and surface treatments. Finishing tools are
316 Technical information