Dodging Dovetail Headaches: 7 Common Dovetail Mistakes

Cutting With Dovetails

While they are specialty tools, dovetail style cutters have a broad range of applications. Dovetails are typically used to cut O-ring grooves in fluid and pressure devices, industrial slides and detailed undercutting work. Dovetail cutters have a trapezoidal shape—like the shape of a dove’s tail. General purpose dovetails are used to undercut or deburr features in a workpiece. O-ring dovetail cutters are held to specific standards to cut a groove that is wider at the bottom than the top. This trapezoidal groove shape is designed to hold the O-ring and keep it from being displaced.

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Avoiding Tool Failure

The dovetail cutter’s design makes it fragile, finicky, and highly susceptible to failure. In calculating job specifications, machinists frequently treat dovetail cutters as larger than they really are because of their design, leading to unnecessary tool breakage. They mistake the tool’s larger end diameter as the critical dimension when in fact the smaller neck diameter is more important in making machining calculations.

As the tools are downsized for micro-applications, their unique shape requires special considerations. When machinists understand the true size of the tool, however, they can minimize breakage and optimize cycle time.

Miniature Matters – Micro Dovetailing

As the trend towards miniaturization continues, more dovetailing applications arise along with the need for applying the proper technique when dovetailing microscale parts and features. However, there are several common misunderstandings about the proper use of dovetails, which can lead to increased tool breakage and less-than-optimal cycle times.

There are seven common mistakes made when dovetailing and several strategies for avoiding them:

1. Not Taking Advantage of Drop Holes

Many O-ring applications allow for a drop hole to insert the cutter into the groove. Take advantage of a drop hole if the part design allows it, as it will permit usage of the largest, most rigid tool possible, minimizing the chance of breakage (Figure 1).

2. Misunderstanding a Dovetail’s True Neck Diameter.

The dovetail’s profile includes a small neck diameter behind a larger end-cutting diameter. In addition, the flute runs through the neck, further reducing the tool’s core diameter. (In the example shown in Figure 2, this factor produces a core diameter of just 0.014″.) The net result is that an otherwise larger tool becomes more of a microtool. The torque generated by the larger diameter is, in effect, multiplied as it moves to the narrower neck diameter. You must remember that excess stress may be placed on the tool, leading to breakage. Furthermore, as the included angle of a dovetail increases, the neck diameter and core diameter are further reduced. O-ring dovetail cutters have an included angle of 48°. Another common included angle for general purpose dovetails is 90°. Figure 3 illustrates how two 0.100″-dia. dovetail tools have different neck diameters of 0.070″ vs. 0.034″ and different included angles of 48° vs. 90°.

3. Calculating Speeds and Feeds from the Wrong Diameter.

Machinists frequently use the wrong tool diameter to calculate feed rates for dovetail cutters, increasing breakage. In micromachining applications where the margin for error is significantly reduced, calculating the feed on the wrong diameter can cause instantaneous tool failure. Due to the angular slope of a dovetail cutter’s profile, the tool has a variable diameter. While the larger end diameter is used for speed calculations, the smaller neck diameter should be used for feed calculations. This yields a smaller chip load per tooth. For example, a 0.083″-dia. tool cutting aluminum might have a chip load of approximately 0.00065 IPT, while a 0.024″-dia. mill cutting the same material might have a 0.0002-ipt chip load. This means the smaller tool has a chip load three times smaller than the larger tool, which requires a significantly different feed calculation.

4. Errors in Considering Depth of Cut.

In micromachining applications, machinists must choose a depth of cut (DOC) that does not exceed the limits of the fragile tool. Typically, a square end mill roughs a slot and the dovetail cutter then removes the remaining triangular-shaped portion. As the dovetail is stepped over with each subsequent radial cut, the cutter’s engagement increases with each pass. A standard end mill allows for multiple passes by varying the axial DOC. However, a dovetail cutter has a fixed axial DOC, which allows changes to be made only to the radial DOC. Therefore, the size of each successive step-over must decrease to maintain a more consistent tool load and avoid tool breakage (Figure 4).

5. Failing to Climb Mill.

Although conventional milling has the benefit of gradually loading the tool, in low-chip load applications (as dictated by a dovetail cutter’s small neck diameter) the tool has a tendency to rub or push the workpiece as it enters the cut, creating chatter, deflection and premature cutting edge failure. The dovetail has a long cutting surface and tooth pressure becomes increasingly critical with each pass. Due to the low chip loads encountered in micromachining, this approach is even more critical to avoid rubbing. Although climb milling loads the tool faster than conventional milling, it allows the tool to cut more freely, providing less deflection, finer finish and longer cutting-edge life. As a result, climb milling is recommended when dovetailing.

6. Improper Chip Flushing.

Because dovetail cuts are typically made in a semi-enclosed profile, it is critical to flush chips from the cavity. In micro-dovetailing applications, chip packing and recutting due to poorly evacuated chips from a semi-enclosed profile will dull the cutter and lead to premature tool failure. In addition to cooling and lubricating, a high-pressure coolant effectively evacuates chips. However, excessive coolant pressure placed directly on the tool can cause tool vibration and deflection and even break a microtool before it touches the workpiece. Take care to provide adequate pressure to remove chips without putting undue pressure on the tool itself. Specific coolant pressure settings will depend upon the size of the groove, the tool size and the workpiece material. Also, a coolant nozzle on either side of the cutter cleans out the groove ahead of and behind the cutter. An air blast or vacuum hose could also effectively remove chips.

7. Giving the Job Away.

As discussed in item number 3, lower chip loads result in significantly lower material-removal rates, which ultimately increase cycle time. In the previous example, the chip load was three times smaller, which would increase cycle time by the same amount. Cycle time must be factored into your quote to ensure a profitable margin on the job. In addition to the important micro-dovetailing considerations discussed here, don’t forget to apply the basics critical to all tools. These include keeping runout low, using tools with application-specific coatings and ensuring setups are rigid. All of these considerations become more important in micro-applications because as tools get smaller, they become increasingly fragile, decreasing the margin of error. Understanding a dovetail cutter’s profile and calculating job specifications accordingly is critical to a successful operation. Doing so will help you reach your ultimate goal: bidding the job properly and optimizing cycle time without unnecessary breakage.

This article was written by Peter P. Jenkins of Harvey Tool Company, and it originally appeared in MicroManufacturing Magazine.

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