The figures shows numerous setting positions of face mill cutters relative to the workpieces. It can be seen that for (a) - (d) the centre of the face mill is within the workpiece. Setting the centre of the face mill close to the centre of the workpiece is the most suitable.
For the favourable examples; D=1.2 ~ 1.3B
For the unfavourable examples; D=B.
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When centre cutting (a)
When centre cutting, a tool with a diameter approx. 1.2～1.3 times that of the workpiece width should be selected.
When the workpiece width is larger than the tool diameter (b) (c)
In situations where the workpiece width is larger than the tool diameter, then machining will need to be carried out in several passes. In this case, the centre of the face mill should be placed within the edge of the workpiece.
When using face mill cutters with
a larger diameter than the workpiece width (d)
If it is necessary to carry out this kind of machining then the positioning of the centre of the face mill should be set to a position in which the maximum number of teeth come into contact with the workpiece.
Unsuitable examples (e) (f)
Unsuitable examples of positioning are when the face mill diameter and the workpiece width are equal as shown in (e). In such a case the surface finish can deteriorate and tool life can be reduced due to excessive rubbing. Another example is (f), in this case the due to the engage angle, the forces exerted on the cutting edge are extremely high and fracturing can occur leading to a reduction in tool life.
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