In CNC production, consistent side-wall quality and stable cutting performance are not achieved by “high speed” alone. They come from a complete machining system—tool geometry, holder rigidity, and a cutting strategy that keeps engagement under control. In this case study, we share a practical four-axis machining process on S45C (HRC20) using our Milling Cutter MW-SE4-10.0*100L paired with a Hydraulic Holder to achieve stable side milling with a repeatable parameter set.
Case illustration diagram
More importantly, this case also reflects what we do as a manufacturing factory: we do not only supply standard tools. Customers can provide their application requirements, and we can manufacture the Milling Cutter and Hydraulic Holder configuration they need for their machining goals.
I. Application Overview: Why This Part Requires a Stable Side Milling Strategy
The toolpath pattern in this project represents a common frame-and-window geometry: an outer contour with an internal “H-shaped” cavity and corner transitions. This type of structure typically creates:
- 1. Long side walls that can amplify vibration.
- 2. Frequent corner engagement changes that cause load spikes.
- 3. Tight local areas where chip evacuation and stability matter.
To handle these factors reliably, we used a “high axial, low radial” engagement strategy that prioritizes stability while maintaining a strong material removal rate.
II. Machine and Setup: Four-Axis Machining Center for Datum Consistency
The process was completed on a four-axis machining center (3+1 indexing). Even for 2.5D cavity work, a four-axis platform offers meaningful advantages:
- 1. One setup supports future multi-face operations without re-clamping.
- 2. Indexing reduces accumulated datum errors in real production workflows.
- 3. It provides a scalable production method for complex parts and repeatable batches.
III. Tooling Configuration: Milling Cutter + Hydraulic Holder
Milling Cutter:
Holder:
Using a Hydraulic Holder supports machining stability through:
- 1. Strong clamping force and improved damping behavior.
- 2. Controlled runout, which helps improve wall finish and dimensional consistency.
- 3. Better repeatability when a process must remain stable over longer production runs.
This combination is especially valuable on side milling operations where overhang and wall height make chatter control a priority.
Tools used in the case study
IV. Cutting Method: Side Milling with High Axial Depth and Low Radial Engagement
The cutting approach applied in this case is defined by:
- Ap = 24 mm (Axial Depth of Cut)
- Ae = 1.5 mm (Radial Width of Cut)
This “high Ap + low Ae” method is widely used to control lateral cutting forces. It reduces chatter risk on long walls and helps maintain stable load conditions through corners and transitions—exactly where many cavity parts become unstable.
V. Fixed Process Parameters for This Case
Work Material: S45C
Hardness: HRC20
Machine: Four-axis machining center
Machining Method: Side milling
Spindle Speed: S = 5000 rpm
Feed Rate: F = 2100 mm/min
Axial Depth: Ap = 24 mm
Radial Width: Ae = 1.5 mm
Milling Cutter: MW-SE4-10.0*100L
Holder: Meiwha Hydraulic Holder
Material Removal Rate (MRR) Reference
A simple performance metric for comparing similar processes is the approximate MRR:
MRR ≈ Ap × Ae × F
= 24 × 1.5 × 2100
= 75,600 mm³/min (≈ 75.6 cm³/min)
This shows the process achieves a solid removal rate while keeping radial engagement controlled for stability.
VI. Why the Hydraulic Holder Matters in This Case
In side milling, the stability of the tool system often determines real-world results more than minor changes in speed and feed. A Hydraulic Holder is especially beneficial when:
- Wall finish consistency matters across long cutting distances.
- Chatter control is required due to overhang or part geometry.
- Repeatable runout performance is needed over multiple production batches.
In this case, the hydraulic clamping system contributes to a more stable tool assembly and helps maintain consistent machining behavior.
VII. Quality and Process Control Notes
Key quality focus points for this type of geometry include:
- Side wall dimensional consistency and finish appearance
- Corner transition quality (avoiding sudden engagement shocks)
- Chip evacuation and prevention of re-cutting
Common process controls used in similar production conditions:
- Constant-load (adaptive/dynamic) roughing to reduce corner load spikes
- Smooth toolpath transitions in internal corners
- Effective coolant/air direction to prevent chip re-cutting
VIII. We Are a Factory: Custom Milling Cutter and Hydraulic Holder Solutions
This case is not only about a single process—it demonstrates our manufacturing capability.
As a factory, we can support customers in two ways:
- 1. Supply standard products such as Milling Cutter and Hydraulic Holder configurations for common machining needs
- 2. Customize tooling based on your real cutting conditions
You can send us your requirements, including:
- · Work material and hardness
- · Part geometry and machining method (side milling, pocketing, finishing, etc.)
- · Machine type and spindle interface
- · Tool diameter/length requirements, flute count, coating preference
- · Holder type requirements (Hydraulic Holder specs, runout target, clamping range)
- · Production goals (tool life, surface finish, cycle time)
We will respond with a practical recommendation and manufacture the Milling Cutter and Hydraulic Holder solution that best matches your application.
The image above shows a hydraulic tool holder customized according to customer requirements.
If you are machining S45C or similar materials and want a stable, repeatable side milling setup, contact us. Share your part and process requirements, and we will produce the Milling Cutter and Hydraulic Holder solution you need—built for your machining conditions and production goals.
Post time: Jan-17-2026
