Square Shoulder Milling is a kind of face milling technique using a cutter with a 90° entering angle to complete the milling progression.
Since this milling technology is recognized as a universal solution, it can help on almost all kinds of milling applications including contouring, ramping, circular, helical and trochoidal interpolation milling, copy milling, plunging and slotting.
In other words, applications of square shoulder milling can be in a large amount.
Square shoulder milling cutter is also a universal cutter for offering almost all kinds of milling operations. The common features of this cutting tool are economy, excellent flexibility, and reliability.
The 90° entering angle on the square shoulder milling cutter efficiently increases the impact force on the workpieces that might cause broken edges and vibrations.
To prevent those situations, materials made of square shoulder milling cutters are usually metals that reach the carbide grade, the design would contain edge geometry. Thus, the risk of damage on cutting tools would be reduced.
There are various designs for this cutting tool, below are popular ones that are used nowadays.
● Two Cutting Edge with Single Side Inserts
1. Suitable for Most Operations
These highly versatile cutters are suitable for most roughing, semi-finishing and finishing operations. Moreover, they provide long lifespan and high precision by the features of reducing heat generation and cutting forces.
2. Protective Coats
They are coated due to the purpose of surface protection and chip preventing. Through this protection, the cutter would neither wear easily nor be attached by the chips produced while milling.
Besides the coated surface, square shoulder milling tools are featured with pre-hardened cutter body with two different pitch configurations and are enabled to have the ability to meet tight tolerances and provide high reliability in a broad range of workpiece materials.
3. Secondary Operation Prevention
Another feature is that millers in this design can mill with a 90° entering angle and can efficiently prevent a secondary operation.
● Four Cutting Edge with Double Side Inserts
1. Cost Less
Square shoulder milling cutters in this design use the most positive helix cutting angle geometry to reach the result of less power consumption and smoother cutting, then get the extra benefit of a longer tool life.
The impressive 90-degree angle accuracy combined with the design of double side inserts has efficiently increased the quality of surface finish, then led to the result of cost reduction.
2. Shorter Operating Duration
Square shoulder milling cutters in this design can significantly shorten your finishing times, then cut down the expense because in manufacturing industries, operating duration (time) means costs (money).
3. Providing a Smoother Surface
This miller makes the finishing operation spend the most time to overall part machining cycle times. Thus, the accurate 90° entering angle can perfectly make the surface of the workpieces smoother and reduce the duration of operation.
4. Less Vibrations and Breakages
The insert cuts used on this miller are designed with less force that can make the vibrations to be minimized and reduce the risk of tool breaking. This leads to extended tool life and smoother surface finish.
● Six Cutting Edge with Double Side Inserts
1. Cost Less
Milling cutters in this design have six triangle cutting blades on one cutter. Thus, the milling duration would be reduced and then decrease the cost of production.
2. Secondary Operation Prevention
The 90° setting angle ensures the surface finishes and the shape of workpieces that the workpieces would not need a secondary operation.
3. Longer Tool Life
The nickel-coated and pre-hardened cutter body can minimize the vibration of the cutters and then provide the max lifespan of the cutter.
● For Heavy Duty Operations
● For Advanced Cutting Material
Square shoulder milling, which is a basic milling operation of face milling, allows the concept of optimized milling cutter to be realized. Moreover, this milling cutter can help to increase productivity efficiently.
When applying the square shoulder milling, the 90° entering angle can be considered as a limiting element. Therefore, the choice of strategy and the cutters, and correct cutting conditions would be extremely important to cover this limit.
When working with square shoulder milling cutters, the best combination of cutting conditions which can provide high security and productivity and low production costs at the same time is cutting deep and with moderate speed and feeding in large.
If the cutting depth or feeding speed are limited due to operational constraints such as dimensions of component, power of machine tool, stability of component or cutting tools, increasing the cutting speed would be a solution to keep the high productivity.
Moreover, by applying average chip thickness speed factor can also optimize operation, especially when the radial cutting depth is less than 30%.
The selection of cutters and cutting edges, such as carbide grade, geometry and dimensions, should be decided according to the selected combination of cutting data. During the milling task, the cutter should be clamped as tight as possible and kept at a proper length in order to prevent unexpectable breaking.
In order to avoid surface hardening of the material, feeding with high speed is required, especially when milling stainless steels, super alloys, and titanium alloys, but it is not allowed to exceed the maximum feed per tooth.
IMTS Exhibition includes manufacturers from around the world. Send us a message with your requirements and our IMTS Experts will happily help you with your questions.