The keyway is often employed for the circumferential fixation of spinning elements in order to transfer torque and torque. This function of the keyway is commonly used. The keyway is an integral component of many different gear transmission methods, in addition to seeing widespread application in mechanical parts. What sort of a cutter is utilized during the milling process of the keyway while the keyway is being processed?
The keyway milling cutter is built with two cutting edges that are symmetrical to each other so that it can counteract the effect of radial cutting force. When milling, the cutting forces on the two cutting edges are combined into a force couple, and the radial forces cancel each other out. This occurs because the two cutting edges are rectangular. Because the cutting edge on the end face of the keyway milling cutter passes through the tool centre, the end face can be milled in the axial direction that the tool is moving in. Both the cylinder and the end face of the keyway milling cutter contain cutting edges. It is equipped with a plunge drilling function and has the ability to immediately process the closed depression. End mills often include a number of cutting blades in excess of three, and they typically feature a central hole in the middle of the end face. As a consequence of this, it is not possible to mill along the axis of the tool, nor can it directly process depressions that are closed. The majority of the time, it is utilized in semi-closed or open processing. Keyway milling cutters are technically classified as a subtype of the end mill.
What exactly is “Keyway Milling”?
The production of a keyway by the use of a milling machine is referred to as “keyway milling.” A “key” is a specific kind of component that is utilized in the process of mechanical transmission. Its primary function is to provide circumferential fixation between the shaft and the components that are mounted on the shaft in order to transmit torque. A few of the keys additionally have the capability of realizing the axial movement or fixing of the pieces on the shaft. The term “keyway” refers to the groove or slot that is machined for the purpose of placing the key. Keyways are typically cut along the axis of the cylindrical surface of a shaft. When a pulley is mounted on a shaft, the keyway on the pulley may make it impossible for the pulley to rotate on the shaft. The keyway can be classified as open type, semi-open type, or closed type depending on the degree of openness it has.
- The cutter teeth are designed as two mutually symmetrical cutter teeth in order to reduce the influence of radial cutting force. Because the radial force of the two cutter teeth cancels each other out during operation, the diameter of the cutter and the rotation of the cutter can be machined at the same time. This allows the cutter to be used more efficiently. The same width throughout the keyways.
- The cutting edge that is located on the cylindrical surface of the keyway milling cutter serves as the primary cutting edge, while the cutting edge that is located on the end surface serves as the secondary cutting edge. It is not possible to move the feed movement in the axial direction of the milling cutter while the machine is operating. The end mill is unable to enter the tool in the axial direction and must instead move in the radial direction in order to enter the tool axially at the same time. On the other hand, the keyway milling cutter is able to enter the tool in the axial direction, making it functionally equivalent to a drill bit and allowing it to drill holes with flat bottoms.
- The keyway milling cutter has a greater cutting capacity than the flat end milling cutter does; this is a distinguishing feature of the two. While keyway milling cutters are used to process keyways, vertical milling cutters are used to process plane or cylindrical surfaces, and the outer diameters of vertical milling cutters are relatively loose. On the other hand, the outer diameters of keyway milling cutters directly affect the matching quality of keyways and keyways, and therefore the tolerance is tighter.
- The outer diameter has a fair amount of accuracy since the size requirements of the keyway after processing are rather high. This ensures that the key will not get dislodged once it has been properly installed. The end mill cannot enter the tool in the axial direction and must move in the radial direction to enter the tool axially at the same time; the keyway milling cutter can enter the tool in the axial direction, which is equivalent to a drill bit and can drill a hole with a flat-bottomed bottom; the end mill cannot enter the tool in the axial direction and must move in the radial direction to enter the tool axially at the same time; and the end mill cannot drill.
The majority of the time, it is utilized in the process of machining keyways. The keyway milling cutter does not have a center hole on its end face, so it may be fed downward like a drill bit. This makes it possible to cut keyways. This indicates that it is able to drill holes with flat bottoms, which are often treated largely in grooves and keyways. Additionally, this indicates that it is versatile.
The majority of the work done with keyways and closed depressions require the use of a specific kind of CNC milling tool known as a keyway milling cutter. In order to neutralize the impact of radial cutting force, the keyway milling cutter is constructed with two cutting edges that are mirror images of each other and are symmetrical to one another. When milling a keyway, there is a certain set of requirements that must be satisfied in reference to the selection of a milling cutter. This decision has an immediate bearing on the precision of the keyway as well as its overall surface roughness. Milling an open keyway often requires the use of an end milling cutter in addition to a keyway milling cutter, while milling a closed keyway normally only requires the use of a disc milling cutter. When milling with an end mill, a hole should be bored at one end of the groove bottom with the same diameter as the milling cutter. This is done so that the hole will line up properly with the milling cutter. It is important that the depth of the hole and the depth of the groove be comparable to one another. The cutting instruments that are utilized throughout the milling process will have an impact, not only on the surface roughness, but also on the overall productivity.
What’s The Difference Between End Mills And Keyway Milling Cutters?
The following is a list of the key differences that may be found between keyway cutters and end mills:
- The end mill normally consists of four or three blades, whereas the keyway milling cutter only consists of two blades (this is useful to ensure the diameter accuracy after re-grinding);
- The primary cutting edge of the end mill is supposed to be situated on the circle of the tool. The primary cutting edge of the keyway milling cutter is positioned on the end face, which is also where the cutting edge that is located on the circular of the keyway milling cutter is located. The end face is also home to the cutting edge of the instrument.
- As a consequence of this, the end mill ought not to be assembled in an axial orientation. It is necessary that it be put to use. It might adopt the shape of a spiral, or it could have a tendency to go toward the knife. The chip pocket on the cutting edge is not very deep, which is one factor that leads to the overall number being on the lower end. During the milling process, the keyway milling cutter makes advantage of an axial feeding motion.
- As a consequence of this, it will wear at the end and predominantly re-grind the end, but it will not re-grind the cutting edge in order to ensure that the machining groove will keep its matching accuracy (H9, N9).
- The aim is something apart from it. The outside diameter of the vertical milling cutter, which may be used to treat surfaces that are either planar or cylindrical, has a fair amount of play in it. In contrast, the outer diameter of the keyway milling cutter, which is used to process keyways, has a direct impact on the quality of matching between keyways and keyways, resulting in a stricter tolerance. This cutter is used to mill keyways.
- There is no standard number of cutter teeth; each cutter has its own unique configuration. When compared to a keyway milling cutter, an end mill typically has a greater than three tooth count, while a keyway milling cutter often only has two teeth count..
- The difference between the blade belt and the There are a lot of edge strips on an end milling cutter because manufacturers wanted to make it so it worked more efficiently.
- The diameter of the tool determines the number of edge strips it has; a standard keyway milling cutter has two edge belts and is designed primarily for axial feed, similar to a drill bit.
- There is a difference in the feed. The end milling cutter is unable to feed in the axial direction; however, it is able to feed in the axial direction when it moves in the radial direction. On the other hand, the keyway milling cutter is able to feed axially straight into the feed, functioning similarly to a drill in that it can create a hole with a flat bottom.
- Vertical milling cutters are used to process plane or cylindrical surfaces, and the outer diameters of these cutters are relatively loose. Keyway milling cutters, on the other hand, are used to process keyways, and the outer diameters of these cutters directly affect the matching quality of keyways and keyways, so the tolerance is tighter.
- End mills have several margins, and the greater the diameter, the more margins there are; keyway milling cutters normally have two margins, and this is primarily so that they may conduct axial feed like a drill bit. This helps enhance the work efficiency of end mills.
- The end mill is unable to enter the tool in the axial direction, so it must move in the radial direction in order to enter the tool axially at the same time. On the other hand, the keyway milling cutter is able to enter the tool in the axial direction, making it functionally equivalent to a drill bit and allowing it to create holes with flat bottoms.
Keyway milling cutters may also be categorized into taper shank keyway milling cutters, straight shank keyway milling cutters, and semicircular keyway milling cutters, according to another classification system. Milling flat keyway requires the use of the taper shank keyway milling cutter, the straight shank keyway milling cutter, and the semicircular keyway milling cutter, whereas milling semicircular keyway requires the use of the semicircular keyway milling cutter.
- Taper Shank Keyway Milling Cutters
Slot drill, quality two flutes, keyway milling cutter, and taper shank are the characteristics of this cutting tool. Milling cutters with taper shank keyways can be used to mill various faces, including step faces, convex faces, concave faces, and milling flat keyways. When cutting a flat keyway, taper shank keyway milling cutters are the most common tool utilised. This link consists of high-speed steel and has a taper shank keyway milling cutters with 2-blade configuration. There are several different round headed flat key seats that can be machined using taper shank keyway milling cutters. These cutters can also be used to mill grooves and bores.
- Straight Shank Keyway Milling Cutters
Keyway milling cutters with straight shanks have cutting edges, and the cutting edge on the end face of the cutter passes through the center of the tool. This allows the cutter to mill in the axial direction of the tool. It is equipped with a plunge drilling function and has the ability to immediately process the closed depression. Milling flat keyways can also be accomplished with keyway milling cutters that have a straight shank.
- Semicircular Keyway Milling Cutter
When milling semicircular keyways, the semicircular keyway milling cutter is the tool that is most commonly used. The high-speed steel material is used in the semicircular keyway milling cutter, and the metric system has a half round handle, which is simple to use and highly practical. Both of these features contribute to the overall quality of the product. The use of a semicircular keyway milling cutter, which is convenient for CNC machining, results in increased productivity. The structure of the semicircular keyway milling cutter is solid, and it possesses high levels of performance and a lengthy lifespan.
What To Look For When Purchasing A Keyway Milling Cutter?
The keyway may be divided into the following categories:
- Open type
- Semi-open type
- The Closed Type
The choice of milling cutter, which is an essential step in the process of milling the keyway, has a direct impact on the precision of the keyway as well as the surface roughness of the keyway. When milling the closed keyway, it is common practice to employ an end mill in addition to a keyway milling cutter. Milling the open keyway, on the other hand, is often accomplished with a disc milling cutter. Milling various keyways requires a selection from the following types of milling cutters:
- Milling Closed Keyway
Milling the closed slot requires the use of an end milling cutter, and the diameter of the tool you pick should be the same as or less than the width of the slot. When its stiffness is inadequate, the end milling cutter has a greater propensity to give under the force that is applied during milling. The cutter can crack if you apply an excessive amount of force to it. If you mill to the required size using the multilayer milling technique, the tool will be lifted above the expansion milling slot; as a result, it will not be possible for the tool to get trapped moving back and forth in the slot. When enlarging the slot, climbing milling should be avoided at all costs to prevent the workpiece from being damaged by gnawing
- Milling A Half-Open Keyway
It is not possible to mill a through-slot using a vertical feed, thus you will need to use a carbide end mill to widen and mill the half-opened keyway. It is recommended to begin by drilling the hole, followed by milling it using an end mill that is narrower than the slot width, and then milling it to the desired width with a milling cutter that is either equal to the slot width or milling it with a shift cutter. Avoid down milling during expansion milling and always feel free to tighten any directions that aren’t being utilised.
- Milling An Open Keyway
In most cases, right-angle grooves and stepped components are what three-sided milling cutters are used for, but in other instances, open keyways may be milled using one of these tools as well. This kind of processing is analogous to how right-angled grooves and stepped pieces are manufactured. The main difference is that when you place the knife on the side, you need to take extra precautions not to scratch the workpiece. This is necessary to ensure that the surface quality of the product is not compromised. The milling process should also pay attention to the use of up-cut milling, and at the same time add coolant. The cooling should be adequate, and it should take place in a timely manner, in order to avoid the tool from being damaged by heat.
Using A Keyway Milling Cutter To Mill The Keyway
The keyway milling cutter is capable of processing a wide variety of keyway varieties. When selecting the tool, you need to pay attention to the trial cutting to ensure that the mistake caused by the tool during the production process does not result in the keyway milling being made bigger than it should be. When milling, it is important to be aware of the distinction between down milling and up milling and to exercise caution so as not to cause a broach phenomenon during down milling. Markings may be drawn on the longitudinal and transverse tables of the machine tool in order to prevent punching from occurring during the cutting process. In conclusion, there are several varieties of keyways. It is required to do an analysis before to processing in order to determine which milling cutter and processing technique should be used for the various kinds of keyways. Utilization that is adaptable to enhance the effectiveness of processing and manufacturing.
A key cutter, sometimes called a keyway cutter or woodruff cutter, is a multipurpose instrument that may be used to cut numerous distinct kinds of keyways. Other names for a key cutter are keyway cutter and woodruff cutter. A keyway milling cutter is an essential instrument that is constructed of a variety of materials and is used for the processing of a wide variety of components. Because of its adaptability and high level of accuracy, the keyway milling cutter is capable of performing a wide range of operations, from the simplest to the most complicated. It comes along with a set of cutting tools as well as a transportable table that can accommodate the formed components. You now have the ability to choose your keyway milling cutter from a variety of end-mill types, including semicircular keyway milling cutters, taper shank keyway milling cutters, and straight shank keyway milling cutters. HUANA is able to help you with all of your individual requirements, regardless of whether you are seeking for new or old equipment.