Ultimate Guide to Road Milling Teeth for Your Cold Milling Machine

08. Nov. 2023

Asphalt milling machines play a critical role in road construction and maintenance. At the heart of these machines lies a critical component – milling teeth. Choosing the right milling teeth and maintaining them is essential for efficiently removing worn-out or damaged asphalt surfaces, preparing roadbeds for new pavement, and ensuring the quality of the finished surface.

In this comprehensive guide, we will explore the anatomy of asphalt milling teeth, factors to consider when selecting the right teeth for your machine, tips for maintaining their quality and longevity and realizing cost savings opportunities.

Table of Contents:
1. The Anatomy of Asphalt Road Milling Teeth
2. Common Challenges Faced by Milling Teeth Components
3. Factors to Consider When Choosing the Right Type of Milling Teeth
4. Tips for Maintaining Milling Teeth Quality and Longevity
5. Maximizing Value and Performance with Everpads Industry-Leading Road Milling Teeth
6. Performance Benchmark: Everpads' T7WS Teeth vs. Market Competitors
7. Concluding Thoughts and Further Exploration

The Anatomy of Asphalt Road Milling Teeth

Asphalt milling machines use a rotating drum equipped with milling teeth to grind and remove asphalt for recycling or disposal. Known as asphalt milling bits or cutters, these teeth are made from durable materials like tungsten carbide to extend their lifespan and withstand the abrasiveness of hard asphalt. The road milling machine teeth consist of several key components that enable them to effectively remove asphalt material during the milling process, including:

Carbide Tip

  • Role: The carbide tip is the cutting edge of milling teeth and is responsible for penetrating materials like asphalt.
  • Material: Typically made from tungsten carbide, a robust alloy known for its durability and hardness.
  • Importance: The composition of the carbide tip is crucial not only for the longevity of the milling teeth but also for their ability to adapt to various surface hardness levels. It must maintain sharpness and strength under stress.

Steel Body

  • Role: Supports the carbide tip structurally and is a critical part of the tooth assembly.
  • Material: Constructed from durable steel or steel alloys that can withstand the operational stress of milling.
  • Functionality: It ensures efficient rotation of the milling tooth, mitigating partial wear which is key to maintaining a consistent lifespan and performance of the tooth.

Wear Plate

  • Role: Provides crucial structural support between the body and the sleeve, aiding in the transmission of force.
  • Protection: Its design helps protect tool holders from the impact and compression stresses that can lead to crushing.
  • Stabilization: Features a centralizing design that ensures efficient body rotation, which promotes a stable and consistent cutting force throughout the operation.

Clamping Sleeve

  • Role: Connects the milling teeth to the tool holder, playing a vital role in the assembly's stability during operation.
  • Function: Ensures a stable cutting force by maintaining proper tension between the tool holder and the teeth, crucial for effective milling.
  • Issues: Any spacing issues within the holder can impact both the lifespan of the clamping sleeve and the teeth, as well as affect the rotation rate of the teeth, potentially leading to uneven wear or operational inefficiencies.

     Anatomy can vary depending on the make and model of the milling machine, the intended application, and other factors. It is crucial to select the right milling teeth and configuration for your machine and the specific job. Moreover, regularly maintaining the milling teeth, helps improve machine efficiency and extend its service life.
 
 


Common Challenges Faced by Milling Teeth Components

The following situations are some common challenges that asphalt milling machine teeth can encounter:
 
  • Premature Failure: Milling teeth fail early due to low-quality carbide tips and flawed manufacturing processes.
  • Partial Wear: Inadequate rotation capability and wear resistance lead to faster wear, reducing the lifespan of the milling teeth.
  • Unbalanced Shaking: Incorrect spacing between the wear plate and steel body causes shaking and tool holder damage.
  • Increased Friction: Partial wear that begins easily increases friction over time, disrupting the consistency and precision of tension, and affecting tooth rotation.

Factors to Consider When Choosing the Right Type of Milling Teeth

When choosing the right milling teeth for your machine, it is critical to consider the following:
 
Material Compatibility: Assess the type of material you'll be milling. Whether it's asphalt, concrete, or another material, each may require a different tooth profile or carbide composition.
 
Milling Application: Surface milling might require a different tooth type compared to fine milling or micro-milling applications.
 
Machine Compatibility: Ensure the teeth are compatible with your milling machine model and brand. Some teeth might be specifically designed for certain machines.
 
Tooth Profile
  • Flat Teeth: Suitable for general purposes, versatile across various milling tasks.
  • Pointed Teeth: Provide a finer finish, ideal for tasks requiring detailed work.
  • Chisel Teeth: Best for breaking through hard surfaces, offering robust performance in challenging conditions.
Tooth Composition
  • Tungsten Carbide Tips: Known for their hardness and durability, making them popular for milling.
  • Carbide Grade: It's crucial to select a carbide grade that is suited to your specific milling application.
Holder Compatibility: Ensure the teeth can be securely mounted to the holders on your machine. A loose fit can lead to premature wear and potential damage.
 
Operational Factors: Consider factors like milling speed and depth. Some teeth might be better suited for high-speed operations, while others might excel in deeper cuts.
 
Durability and Lifespan: Opt for teeth known for their durability and long lifespan, especially if you plan to use them intensively.
 
Cost vs. Quality: While cost is a factor, it's essential to weigh it against the teeth's quality. Investing in higher-quality teeth might be more cost-effective in the long run due to reduced replacement frequency and downtime.
 
Manufacturer Reputation: Choose a reputable manufacturer known for producing reliable and high-quality milling teeth.

Tips for Maintaining Milling Teeth Quality and Longevity

The following are some tips to improve milling teeth condition and extend their lifespan:
  • Regular Inspection: Frequently check the wear of the teeth. This helps in timely identification and replacement of excessively worn teeth.
  • Cleaning: After each use, clear any residual debris or build-up. This can reduce unnecessary wear and maintain optimal performance of the teeth.
  • Proper Storage: Ensure the milling teeth are stored in a dry, cool place away from direct sunlight and extreme temperatures when not in use.
  • Use the Correct Teeth: Choose the appropriate teeth based on the material being milled. Using incorrect teeth may result in premature wear.
  • Appropriate Milling Speed and Depth: Follow the manufacturer's guidelines to determine milling speed and depth to prevent unnecessary stress and wear.
  • Regular Sharpening: If the teeth are sharpenable, regular sharpening can enhance their lifespan.
  • Replace Damaged Components: Regularly inspect and replace any worn or damaged components, like the bolts fixing the teeth or parts of the milling machine.
  • Use Professional Lubricants: Employing the appropriate lubricants can reduce friction and wear on the teeth.
  • Avoid Over-milling: Understand the limits of your milling machine and avoid operating it under overload.
  • Continuous Training: Ensure operators are well-acquainted with the correct operation and maintenance procedures of the milling machine.
 
Following these and other tips can not only significantly extend the lifespan of your milling teeth, but ensure that your machines are operating at peak efficiency and producing high-quality results.

Maximizing Value and Performance with Everpads Industry-Leading Road Milling Teeth

Everpads is a leading manufacturer of high-quality asphalt milling teeth. With over 20 years of experience, we have honed our manufacturing processes to produce the most reliable and high-performing asphalt milling teeth industry.
 
Our GeN-E milling teeth include the following features and components:
 
Carbide Tip
  • Construction: Crafted in a high-pressure environment using an advanced sintering furnace.
  • Materials: Sourced from a leading global provider to ensure top quality.
  • Features: Offers up to 95 HRC hardness to withstand the intense cutting forces of milling operations.
Steel Body
  • Material: Made from a special high wear-resistant alloy steel.
  • Design: Features a proprietary wave shape for increased rotational efficiency, enhanced tool holder protection, and extended lifespan of milling teeth.
Wear Plate
  • Design: Wave-shaped for improved centralization of the body.
  • Specifications: 4mm thick and 48mm in diameter, providing robust protection against crushing and prolonging service life.
Clamping Sleeve
  • Material and Treatment: Constructed from a special material with advanced heat treatment.
  • Functionality: Ensures precise and durable tension for milling teeth within the tool holder, promoting smooth rotation and effectively reducing internal friction and wear.

Performance Benchmark: Everpads' T7WS Teeth vs. Market Competitors

Above, we discussed some tips for maintaining milling teeth quality and longevity. Here, we focus on the correlation between milling teeth quality and replacement costs. In the graph below, the blue line represents milling teeth of average quality, while the others represent higher quality teeth from leading manufacturers, including Everpads. 

 

We can see that the average milling area of Everpads' T7ws is approximately 15,000-16,000 square meters without premature failure. The partial wear rate is 2% lower than the market average.

Cost-Benefit Analysis

Replacement frequency comparison:
To illustrate the potential cost savings between Everpads and the other manufacturers, it is useful to consider an example. Suppose you operate the W210 asphalt milling machine for 1,200 hours per year, milling 14,000 square meters every 30 hours. If you choose the K Brand Teeth with a lifespan of 9,000 square meters, then based on your usage you will need to replace the teeth more than 60 times per year.
 
However, if you select Everpads road milling teeth, you will only need to replace the teeth 40 times per year. As a result, your company realizes cost savings of $79,200.
Moreover, the higher-quality teeth provide adequate protection to the tool holder, result in less downtime, and produce a higher-quality surface.
 
 
 
 
Cost Comparison: Yearly Savings Breakdown by Brand

Now let's consider potential cost savings for other milling components. Suppose you equip the W210 (model 2020) with the fine milling drum (LA:6*2mm, Max.FT 30mm, Part.No 2112478), you need to purchase 176 teeth per replacement, and if you replace with W brand teeth your expense is around $880 dollars(5*176). However, with Everapds, your costs are just $704 per(4*176) replacement.

With the K brand needs you will need to spend around $52,800 (880*60 times) per year, the W brand needs $42,240 (880*48 times) per year, and with Everpads your costs are $28,160 (704*40 times) per year. W brand cut down your expenses by around $10,560 per year against K brand, Everpads cut down your expenses by around $90,000 against K Brand per year, and $14,080 against W brand per year.

And values above are only in numbers, Everpads teeth have better cutting efficiency and lesser premature failure, and most importantly our R&D designs show how much we care about each of our clients. Everpads lists the factual states because we don't boast, we believe in facts, and being loyal to the facts and customer is our brand value.

Concluding Thoughts and Further Exploration

In this article, we explored asphalt road milling teeth in detail, including their components, factors to consider when selecting the right teeth for your machine, and tips for maintaining their quality and longevity. Moreover, we discussed how the quality of asphalt milling teeth impacts service life and performance. We explored some key features that Everpads incorporates into our industry-leading road milling teeth and how choosing Everpads can help your organization realize significant cost savings.

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For those still seeking guidance on evaluating your machine's teeth, we've crafted another comprehensive blog post that delves deeper into this subject. Explore it for a more detailed understanding.