How Dynamic Milling Works

   Dynamic milling is a strategy that is becoming more and more popular due to its improved material removal rates while still maintaining process security compared to traditional milling strategies.  Incorporating two different machining strategies creates the concept and allows advantages not realized before.

   Radial chip thinning is the first strategy exploited in dynamic milling.

   This is the phenomenon of creating a smaller chip by engaging a small percentage of the tool diameter (less than half).  When less than half the tool diameter is engaged in the cut, the average chip thickness is less than the advance per tooth.  10-20% radial engagement of the tool diameter results in a significant reduction in average chip thickness, and we need to be aware of this.  The average chip thickness should still meet the tool manufacturer’s recommendation for chip load.  If it doesn’t, then we are not maximizing the tool’s capability.  It also can result in the chip not being physically large enough to hold the heat produced by the cutting operation.  A small chip has less capability to hold heat which results in either the tool or the workpiece absorbing this latent heat, which is undesirable.  Feeding the tool faster is the solution to preventing excessive radial chip thinning, which is a nice “solution” to incorporate.