Service Home How To Procedures Mill - Surface Finish - Test Cut Procedure - AD0647
Last updated: 11/04/2025

Mill - Surface Finish - Test Cut Procedure

AD0647

Revision B - 11/2025

Mill - Surface Finish - Test Cut Procedure - Intro

Test Cut Description:

Use the following test kits and procedure to determine the root cause of the mill surface finish issues.

Perform all troubleshooting listed in the Mill chatter troubleshooting guide.

MILL Chatter Troubleshooting

In addition to the inspections listed, perform the following:

After checking the above and if the surface issue continues, select the test cut kit that applies to your machine.

Inch Test Cut Kit:

  • EK-0026 CT40 MILL SURFACE FNSH TEST CUT KIT IN
  • EK-0027 BT40 MILL SURFACE FNSH TEST CUT KIT IN
  • EK-0028 CT50 MILL SURFACE FNSH TEST CUT KIT IN
  • EK-0029 HSK63A MILL SURFACE FNSH TEST CUT KIT IN

Metric Test Cut Kit:

  • EK-0030 SK40 MILL SURFACE FNSH TEST CUT KIT MM
  • EK-0031 BT40 MILL SURFACE FNSH TEST CUT KIT MM
  • EK-0032 CT50 MILL SURFACE FNSH TEST CUT KIT MM
  • EK-0033 HSK63A MILL SURFACE FNSH TEST CUT KIT MM

Run the Mill Surface Finish test cut program. This is a proven program to determine the root cause of the mill surface finish issues.

Machine Requirements:

  • Latest Released Software Version
  • Properly milled jaws
  • 6061 Aluminum 3 Inch x 3 Inch Bar Cut To 0.75 Inch

Inch Part Program:

O00007.nc

Metric Part Program:

O00008.nc

Mill - Surface Finish - Test Cut Procedure - Equipment List

Inch

EK0026 - CT40 Equipment List
E-Comm PN Quantity Description
01-0159 1 HSCM45-.06" -.83"-.75W
02-0505 1 TCX16R-HC HU-30
03-0573 1 1/2" 3FL HI PERF ALUM EM W .030" RADIUS
04-0004 1 CT40-EM.75-1.75
04-0010 1 CT40-ER32-2.5
04-0250 1 ER32-13 MM COLLET
04-0292 2 CT40 PULL STUD SOLID 1 EACH
EK-0027 - BT40 Equipment List
E-Comm PN Quantity Description
01-0159 1 HSCM45-.06" -.83"-.75W
02-0505 1 TCX16R-HC HU-30
03-0573 1 1/2" 3FL HI PERF ALUM EM W .030" RADIUS
04-0149 1 BT40-ER32-70
04-0160 1 BT40-EM.750-63
04-0250 1 ER32-13 MM COLLET
04-0296 2 BT40 PULL STUD SOLID 1 EACH
EK-0028 - CT50 Equipment List
E-Comm PN Quantity Description
01-0159 1 HSCM45-.06" -.83"-.75W
02-0505 1 TCX16R-HC HU-30
03-0573 1 1/2" 3FL HI PERF ALUM EM W .030" RADIUS
04-0033 2 C50-ER32-4 COLLET CHUCK
04-0250 1 ER32-13 MM COLLET
04-0257 1 ER32-20 MM COLLET
04-0294 2 CT50 PULL STUD SOLID 1 EACH
EK-0029 - HSK63A Equipment List
Part Number Quantity Description
01-0159 1 HSCM45-.06" -.83"-.75W
02-0505 1 TCX16R-HC HU-30
03-0573 1 1/2" 3FL HI PERF ALUM EM W .030" RADIUS
04-0250 1 ER32-13 MM COLLET
04-0257 1 ER32-20 MM COLLET
04-0261 2 HSK63A-ER32-100

Metric

EK-0300 - Metric SK40 Equipment List
E-Comm PN Quantity Description
01-0526 1 HSCM 1600-20W
02-0505 1 TCX16R-HC HU-30
03-1016 1 12MM 3FL HI PERF END MILL 1MM RAD
04-0507 2 SK40-ER32-100
04-0249 1 ER32-12 MM COLLET
04-0257 1 ER32-20 MM COLLET
04-0914 2 SK40/DIN PULL STUD - 1EACH
EK-0031 - Metric BT40 Equipment List
E-Comm PN Quantity Description
01-0526 1 HSCM 1600-20W
02-0505 1 TCX16R-HC HU-30
03-1016 1 12MM 3FL HI PERF END MILL 1MM RAD
04-0149 2 BT40-ER32-70
04-0249 1 ER32-12 MM COLLET
04-0257 1 ER32-20MM COLLET
04-0296 2 BT40 PULL STUD SOLID 1 EACH
EK-0032 - Metric CT50 Equipment List
E-Comm PN Quantity Description
01-0526 1 HSCM 1600-20W
02-0505 1 TCX16R-HC HU-30
03-1016 1 12MM 3FL HI PERF END MILL 1MM RAD
04-0032 2 CT50-ER32-2 COLLET CHUCK
04-0249 1 ER32-12 MM COLLET
04-0257 1 ER32-20 MM COLLET
04-0294 2 CT50 PULL STUD SOLID 1 EACH
EK-0033 - METRIC HSK63A EQUIPMENT LIST
Part Number Quantity Description
01-0526 1 HSCM 1600-20W
02-0505 1 TCX16R-HC HU-30
03-1016 1 12MM 3FL HI PERF END MILL 1MM RAD
04-0249 1 ER32-12 MM COLLET
04-0257 1 ER32-20 MM COLLET
04-0261 2 HSK63A-ER32-100

Mill - Surface Finish - Test Cut Procedure - Tools

Tool Number 1:

Cutter Type: ½” End Mill 3 Flute with .030" Radius

Holder Type: ER Collet

RPM: 10,000

Number of  Flutes: 3

Minimum Working Length: 1.75"

Tool Number 2:

Cutter Type: ” ¾” Chamfer Tool

Holder Type: Weldon or ER Collet

RPM: 10,000

Number of  Flutes: 1

Minimum Working Length: 2.50"

Mill - Surface Finish - Test Cut Procedure

A vise must grip the stock 0.150"-0.200”. The outside profile is .500” deep so 0.200” is the max.

Set G54 Offsets:

  • Set tool length offsets off top of material
  • Set G54 X0 Y0 to center of material
  • Set G54 Z0 to top of material

1

Run the Mill Surface Finish test program.

  • Inspect the finished part, look for chatter and coining.
  • If no chatter or coining found, then the machine performs as intended.
  • If chatter or coining is found, generate an error report, pictures and send along with machined part to the factory.

2

Test Cut part with Coining.