Chipbreaker Tooling: More Than Roughing – Enhancing Cutting Performance

When many people think about solid carbide tools with chip breakers, they are usually tooling up for a roughing application. While the chipbreaker tool is a great choice for such applications, it can be utilized in a number of other areas too. In this post, we’ll examine many other benefits of the chip breaker style of tooling.

High Efficiency Milling (HEM)

High Efficiency Milling (HEM) uses CAM software to program advanced toolpaths that reduce cutting forces. These tool paths employ smaller end mills with a higher number of flutes (for a stronger core) running at higher speeds and feeds. This strategy includes a light radial depth of cut (RDOC), high axial depth of cut (ADOC), and a controlled angle of engagement.

Helical’s chipbreaking tools include serrated indents along the edge of flute for the entire length of cut. Because HEM utilizes heavy axial depths of cuts, these tools are able to break long chips into smaller ones. In addition to improving chip control and reducing cutting resistance, chipbreaker tools also help in decreasing heat load within the chips. This delays tool wear along the cutting edge and improves cutting performance. 

Check out this testimony from a Helical Solutions customer:

“We were able to get going with the 7 flute tools with the chipbreaker. I have to say the difference was INCREDIBLE! We can now rough the entire part with one tool. Also, the operator doesn’t have to open the door to clear chips hardly at all. We were able to rough and finish a 4.15 dia. bore 2 inches deep through the part without having to clear chips at all. Before we had to clear the chips out at least 15-20 times. Many thanks for your support.”

Slotting

When slotting, a major concern is chip control. A large buildup of chips can cause the recutting of chips, which adds a lot of heat back into the tool. Chip buildup can also cause a heavy amount of chattering. Both of these conditions are detrimental to tool life. A chip breaking tool can help reduce chip build-up when slotting which will extend tool life. Remember when slotting that 4 flute tools should be utilized in steel. For aluminum and other non- ferrous materials, a 3 flute tool is best.

Trochoidal Slotting

Trochoidal slotting is a form of slotting that uses HEM techniques to form a slot. Trochoidal milling implements a series of circular cuts to create a slot wider than the cutting tool’s cutting diameter. Using the logic listed in the earlier paragraphs of this article, a chipbreaker should be used when performing this operation.

Advantages of Trochoidal Slotting:

Decreased cutting forces

Reduced heat

Greater machining accuracy

Improved tool life

Faster cycle times

One tool for multiple slot sizes

Finishing

A little known fact about Helical’s chipbreaker style tool is that the chip breakers are offset flute to flute, which allows for a quality finish on the walls of the part. When utilizing light depths of cuts, high-quality finishes can be achieved.