The final shape of the workpiece plays a fundamental, but also important, role in the selection of rough tooling. Choosing the wrong cutting tool can generate additional steps in the process, reduce profitability, and negatively impact delivery.
For grooves, step milling, face milling to the shoulders, and most 2-d milling, the shoulder tools are the most reasonable. Using a button cutter in these cases will make it necessary to take additional steps to process the radius of the round insert, adding an additional tool for the program and Settings. In these cases, a circular insert also leaves a fan wall complete, creating a need to clean the line.
For an open face, a button cutting tool is a reasonable choice for a 3-d copy, cavity/core roughing, surface or face milling. In most cases, the final surface has only one wall. The use of round inserts (especially in lighter cutting depths) creates a smooth, flowing surface that is easier to cut during semi-finishing or finishing. The shoulder tool leaves the steps on such a surface, resulting in an unbalanced tool pressure and poor surface tolerance. The part of the shoulder tool usually requires a semi-finishing or cutting to achieve the required contour tolerances. In addition, on cutting tools, the stepped surface is more rigid, cutting tool pressure is too high, reducing tool life and surface finish.
There are many different approaches to interpolation in the hole, most of which are slow. According to the type of machine tool, the cycle time can be significantly improved, especially in the 2-inch (51-mm) diam or larger hole.
Square shoulder milling tool is more suitable for round interpolation than buckles. This process involves drilling a pre-drilled hole that is larger than the cutting tool. Then, the shoulder tool is put into the hole, in which the size of the circle is measured in the depth of each cut, and the depth is continued in this way.
