Improve Workpiece Finish with Different End Mill Cutting Tools

End mills play an important role in improving the surface finish of workpieces. By selecting suitable tool materials, optimizing tool geometry parameters and cutting parameters, the surface quality of workpieces can be effectively improved, thereby improving product quality, reducing processing costs and improving processing efficiency. In practical applications, it is necessary to comprehensively consider factors such as workpiece materials and processing requirements to select suitable end mills and cutting processes.

Improving the Finish of Different Steel Workpieces

Improving the Finish of Carbon Steel Workpieces

Carbon steel has moderate hardness and is prone to forming built-up edge (BUE) during cutting, which will cause the cutting edge of the end mill cutting tool to become blunt, thereby affecting the surface finish. At the same time, the heat generated during the cutting process will cause oxidation and discoloration on the workpiece surface, affecting the surface quality.

How to Improve the Finish of Carbon Steel Workpieces

• Use sharp high-speed steel (HSS) or carbide end mill tools, and check and replace cutting tools every processing period to reduce the formation of built-up edge.
• The cutting speed is controlled at 100-150 m/min and the feed rate is controlled at 0.1-0.3 mm/rev to reduce cutting heat.
• Make full use of cooling lubricants, use emulsion or oil-based coolants, and continuously spray the cutting area to reduce the cutting temperature and prevent the surface oxidation and discoloration of the workpiece.

Improve the Finish of Low-carbon Steel Workpieces

Low-carbon steel materials are soft and sticky, and it is easy to accumulate chips on the end mill tool, forming built-up edges, which affects the finish. In addition, low-carbon steel is prone to burring during cutting, resulting in increased surface roughness.

How to Improve the Finish of Low-carbon Steel Workpieces

• Use coated end mill tools, such as TiN or TiAlN coated cutting tools, to reduce the formation of built-up edges, and check the cutting tool status regularly.
• The cutting speed is controlled at 200-250 m/min and the feed rate is controlled at 0.05-0.2 mm/rev to reduce burring.
• Use high-pressure coolant to prevent chips from accumulating on the end mill tool and keep the cutting area clean by increasing the flow and pressure of the coolant.

Improve the Finish of Medium Carbon Steel Workpieces

Medium carbon steel has moderate hardness but high toughness. It is easy to produce vibration and end mill tool wear during cutting, affecting the surface finish. At the same time, the change in hardness after heat treatment may make it more difficult to select end mill tools and adjust cutting parameters during processing.

How to Improve the Finish of Medium Carbon Steel Workpieces

• Choose carbide end mill tools and use anti-vibration end mill tool fixture systems to reduce vibration during cutting.
• The cutting speed is controlled at 80-120 m/min and the feed rate is controlled at 0.1-0.25 mm/rev to reduce tool wear.
• Fine machining is performed after heat treatment to ensure uniform material hardness and avoid surface defects caused by hardness changes.

Improve the Finish of High Carbon Steel Workpieces

High carbon steel has high hardness and causes severe wear on end mill tools, which can easily cause the tool to be quickly blunted, thereby reducing the surface finish. In addition, high carbon steel is prone to brittle fracture and thermal cracking during cutting, and these defects will affect the surface quality.

How to Improve the Finish of High Carbon Steel Workpieces

• Use ceramic end mills or CBN end mills with good wear resistance, and replace the tools regularly to maintain cutting performance.
• Control the cutting speed at 50-80 m/min and the feed rate at 0.05-0.15 mm/rev to reduce tool wear.
• Use high-efficiency coolant, especially oil-based coolant, to ensure effective cooling of the cutting zone to prevent thermal cracks and brittle fractures.

Improve the Finish of Different Stainless Steel Workpieces

Improve the Finish of 304 Stainless Steel Workpieces

Stainless steel 304 has high toughness and corrosion resistance, but it is prone to built-up edge (BUE) during cutting, resulting in increased wear of the end mill tool and decreased surface finish. In addition, surface discoloration and hardening are prone to occur at high temperatures.

How to Improve the Finish of 304 Stainless Steel Workpieces

• Use coated carbide end mills, such as TiAlN coating, to reduce the formation of built-up edge.
• Cutting speed is controlled at 100-150 m/min, feed rate is controlled at 0.05-0.2 mm/rev, reduce the influence of cutting heat and built-up edge.
• Use high-efficiency coolant to ensure sufficient cooling and prevent surface discoloration and hardening under high temperature.

Improve the Finish of 316 Stainless Ssteel Wworkpiece

Stainless steel 316 has higher corrosion resistance and higher strength, but it is also prone to formed built-up edge, leading to cutting tool wear and surface finish problems. In addition, heat accumulation is easy to occur during cutting, leading to hardening of the workpiece surface.

How to Improve the Finish of 316 Stainless Ssteel Wworkpiece

• Choose high wear resistance coated end mill tools, such as TiCN coated end mill tools, to reduce the influence of built-up edge.
• Cutting speed is controlled at 80-130 m/min, feed rate is controlled at 0.05-0.2 mm/rev, and reduce cutting heat.
• Use high-pressure cooling system to ensure sufficient cooling of the cutting zone to prevent heat accumulation and surface hardening.

Improve the Finish of 410 Stainless Steel Workpieces

Stainless steel 410 is a martensitic stainless steel with high hardness. It is easy to generate high cutting force and end mill tool wear during cutting. In addition, brittle fracture is prone to occur during cutting, affecting the surface finish.

How to Improve the Finish of 410 Stainless Steel Workpieces

• Use high-hardness ceramic end mill tools or CBN end mill tools to cope with high hardness and reduce cutting tool wear.
• The cutting speed is controlled at 50-100 m/min and the feed rate is controlled at 0.05-0.15 mm/rev to reduce cutting force and vibration.
• Use oil-based coolant with good cooling effect to ensure good cooling of the cutting area and prevent brittle fracture.

Improve the Finish of 420 Stainless Steel Workpieces

Stainless steel 420 is also a martensitic stainless steel with high hardness. It is easy to generate high cutting force and end mill tool wear during cutting. In addition, thermal cracks and brittle fracture are prone to occur, affecting the surface quality.

How to Improve the Finish of 420 Stainless Steel Workpieces

• Choose CBN or ceramic end mills with good wear resistance, check and replace end mills regularly to maintain cutting performance.
• Control the cutting speed at 40-80 m/min and the feed rate at 0.03-0.1 mm/rev to reduce cutting tool wear and cutting force.
• Use efficient cooling lubricants, especially oil-based coolants, to ensure sufficient cooling of the cutting area to prevent thermal cracks and brittle fractures.

Improve the Finish of 430 Stainless Steel Workpieces

Stainless steel 430 is a ferritic stainless steel. It is easy to produce chip adhesion and built-up edge during cutting, resulting in a decrease in surface finish. In addition, vibration is easy to occur during cutting, affecting the surface quality.

How to Improve the Finish of 430 Stainless Steel Workpieces

• Use sharp carbide end mills and choose coated end mills with good anti-adhesion properties, such as TiN or TiAlN coatings.
• Cutting speed is controlled at 100-150 m/min, feed rate is controlled at 0.05-0.2 mm/rev, and chip adhesion and built-up edge are reduced.
• Use high-pressure cooling system to ensure sufficient cooling and lubrication of cutting zone, reduce vibration and surface defects.

Improve the Finish of Different Sluminum Alloy Workpieces

Improve the Finish of 1050 Aluminum Workpieces

Aluminum 1050 is a pure aluminum with high ductility and thermal conductivity, but it is easy to produce built-up edge (BUE) during cutting, resulting in a decrease in surface finish. In addition, soft materials are prone to accumulate chips on the end mill tool, affecting the cutting effect.

How to Improve the Finish of 1050 Aluminum Workpieces

• Use sharp carbide end mill tools and keep the cutting tools sharp to reduce the formation of built-up edge.
• Cutting speed is controlled at 200-400 m/min, feed rate is controlled at 0.1-0.3 mm/rev, and chip accumulation is reduced.
• Use high-efficiency cooling lubricant to ensure good cooling and lubrication of the cutting zone to prevent chip adhesion.

Improve the Finish of 2024 Aluminum Copper Alloy Workpieces

Aluminum 2024 is an aluminum-copper alloy with high strength, but it is easy to produce built-up edge and surface scratches during cutting, affecting the finish. In addition, the material has a high hardness, which is easy to cause end mill tool wear.

How to Improve the finish of 2024 aluminum-copper alloy workpieces

• Choose coated carbide end mill tools, such as TiAlN coated cutting tools, to reduce the formation of built-up edge and tool wear.
• The cutting speed is controlled at 150-300 m/min and the feed rate is controlled at 0.05-0.2 mm/rev to reduce surface scratches.
• Use emulsion or oil-based coolant to ensure sufficient cooling and lubrication to prevent chip adhesion and tool wear.

Improve the Finish of 5052 Aluminum Magnesium Alloy Workpieces

Aluminum 5052 is an aluminum-magnesium alloy with high corrosion resistance and medium strength, but it is easy to produce built-up edge during cutting, resulting in a decrease in surface finish. In addition, sticking is prone to occur during cutting.

How to Improve the Finish of 5052 Aluminum Magnesium Alloy Workpieces

• Use sharp carbide milling cutter tools, and regularly check and replace end mills to reduce built-up edge and sticking.
• Control the cutting speed at 180-350 m/min and the feed rate at 0.1-0.25 mm/rev to reduce surface defects.
• Use efficient cooling and lubricating fluid to ensure good cooling and lubrication of the cutting area to prevent sticking and built-up edge.

Improve the Finish of 6061 Aluminum Silicon Magnesium Alloy Workpieces

Aluminum 6061 is an aluminum-silicon-magnesium alloy with good mechanical properties and machinability, but it is easy to produce built-up edge and surface scratches during cutting. In addition, the material has medium hardness, which is easy to cause milling cutter tool wear.

How to Improve the Finish of 6061 Aluminum Silicon Magnesium Alloy Workpieces

• Choose coated carbide milling cutter tools, such as TiCN coated cutting tools, to reduce the formation of built-up edge and tool wear.
• The cutting speed is controlled at 150-300 m/min, and the feed rate is controlled at 0.05-0.2 mm/rev to reduce surface scratches.
• Use high-efficiency coolant to ensure adequate cooling and lubrication to prevent chip adhesion and tool wear.

Improve the Finish of 7075 Aluminum Zinc Alloy Workpieces

Aluminum 7075 is a high-strength aluminum-zinc alloy with excellent mechanical properties, but it is easy to produce built-up edge and surface scratches during cutting, affecting the finish. In addition, high-hardness materials are prone to milling tool wear.

How to improve the finish of 67075 aluminum-zinc alloy workpieces

• Use high-hardness carbide milling cutter tools, and choose coated milling cutter tools with good anti-adhesion properties, such as TiAlN coatings.
• The cutting speed is controlled at 100-250 m/min, and the feed rate is controlled at 0.05-0.2 mm/rev to reduce built-up edge and surface scratches.
• Use high-efficiency cooling and lubricating fluid to ensure good cooling and lubrication of the cutting area, reduce tool wear and chip adhesion.

Improving the Finish of Different Alloy Steel Workpieces

Improving the Finish of 4140 Alloy Steel Workpieces

Alloy steel 4140 is a medium carbon chromium-molybdenum alloy steel with high strength and toughness, but it is prone to high cutting forces and built-up edge (BUE) during cutting, which affects the surface finish. In addition, high hardness materials are prone to milling cutter tool wear.

How to Improving the Finish of 4140 Alloy Steel Workpieces

• Use high-hardness carbide milling cutter tools and choose wear-resistant coating cutting tools, such as TiAlN coating, to reduce cutting tool wear and built-up edge.
• The cutting speed is controlled at 60-100 m/min and the feed rate is controlled at 0.05-0.2 mm/rev to reduce high cutting forces and the formation of built-up edge.
• Use high-efficiency cooling and lubricating fluid to ensure sufficient cooling and lubrication of the cutting area to prevent tool wear and built-up edge.

Improve the Finish of 4340 Alloy Steel Workpiece

Alloy steel 4340 is a high-strength, impact-resistant nickel-chromium-molybdenum alloy steel. It is easy to generate high cutting forces and built-up edges during cutting, resulting in milling cutter tool wear and reduced surface finish. In addition, work hardening is easy to occur during cutting.

How to Improve the Finish of 4340 Alloy Steel Workpiece

• Use high-temperature resistant and high-hardness cutting tool materials, such as ceramic milling cutter tools or CBN milling cutter tools, and choose wear-resistant coating cutting tools, such as TiCN coating, to reduce tool wear and built-up edges.
• The cutting speed is controlled at 50-90 m/min and the feed rate is controlled at 0.05-0.2 mm/rev to reduce work hardening and built-up edges.
• Use high-pressure coolant to ensure sufficient cooling and lubrication of the cutting area to prevent high temperature from causing tool wear and work hardening.

Improve the Finish of 8620 Alloy Steel Workpiece

Alloy steel 8620 is a low-carbon nickel-chromium-molybdenum alloy steel with good toughness and machinability, but it is easy to generate built-up edges and high cutting forces during cutting, affecting the surface finish. In addition, vibration and cutting tool wear are prone to occur during the cutting process.

How to Improve the Finish of 8620 Alloy Steel Workpiece

• Use sharp carbide end mills and select coated milling cutters with good anti-adhesion properties, such as TiN coatings, to reduce built-up edge and cutting tool wear.
• The cutting speed is controlled at 70-110 m/min and the feed rate is controlled at 0.05-0.2 mm/rev to reduce high cutting forces and vibrations.
• Use efficient cooling and lubricating fluid to ensure sufficient cooling and lubrication of the cutting area to prevent built-up edge and tool wear.

Improve the Finish of 52100 Alloy Steel Workpieces

Alloy steel 52100 is a high-carbon chromium bearing steel with high hardness and wear resistance, but it is prone to high cutting forces and cutting tool wear during cutting. In addition, heat accumulation and thermal cracks are prone to occur during cutting, affecting the surface finish.

How to Improve the Finish of 52100 Alloy Steel Workpieces

• Use high-hardness ceramic end mills or CBN end mills, and choose high-temperature resistant coated cutting tools, such as TiAlN coatings, to reduce tool wear and high cutting forces.
• The cutting speed is controlled at 40-80 m/min and the feed rate is controlled at 0.05-0.15 mm/rev to reduce heat accumulation and thermal cracks.
• Use high-efficiency coolant to ensure sufficient cooling and lubrication of the cutting area to prevent tool wear and thermal cracks caused by high temperatures.

Improve the Finish of Different Titanium Steel Workpieces

Improve the Finish of Pure Titanium Workpieces

Pure titanium has excellent strength and corrosion resistance, but it is prone to adhesion and built-up edge (BUE) during cutting, resulting in a decrease in surface finish. In addition, titanium has poor thermal conductivity and is prone to high temperatures during cutting, resulting in increased wear of the milling cutter.

How to Improve the Finish of Pure Titanium Workpieces

• Use sharp carbide end mills and choose coated milling cutters with good anti-adhesion properties, such as TiAlN coatings, to reduce the formation of built-up edge.
• The cutting speed is controlled at 30-60 m/min and the feed rate is controlled at 0.05-0.2 mm/rev to reduce cutting heat and adhesion.
• Use high-pressure coolant to ensure sufficient cooling and lubrication of the cutting area to prevent tool wear caused by high temperature.

Improve the Finish of TC4 Titanium Alloy Wworkpieces

Titanium alloy TC4 (Ti-6Al-4V) has high strength and corrosion resistance, but it is also prone to built-up edge and adhesion during cutting, affecting the surface finish. In addition, the thermal conductivity of titanium alloy is poor, and the cutting heat is concentrated in the cutting area, causing the end mill tool to wear quickly.

How to Improve the Finish of TC4 Titanium Alloy Wworkpieces

• Use high-hardness carbide end mill tools and choose wear-resistant coating milling tools, such as TiAlN coating, to reduce built-up edge and cutting tool wear.
• The cutting speed is controlled at 20-50 m/min and the feed rate is controlled at 0.03-0.15 mm/rev to reduce cutting heat and adhesion.
• Use efficient coolant, especially oil-based coolant, to ensure adequate cooling and lubrication of the cutting zone to prevent tool wear caused by high temperature.

Improve the Finish of Different Copper Alloy Workpieces

Improve the Finish of C11000 Pure Copper Workpieces

Copper C11000 is pure copper with good electrical and thermal conductivity, but it is easy to produce built-up edge (BUE) during cutting, resulting in a decrease in surface finish. At the same time, copper is soft and it is easy to accumulate chips on the milling cutter tool.

How to Improve the Finish of C11000 Pure Copper Workpieces

Use sharp carbide end mill tools, and regularly check and replace milling cutter tools to reduce the formation of built-up edge

• Use sharp carbide end mill tools, and regularly check and replace milling cutter tools to reduce the formation of built-up edge.
• The cutting speed is controlled at 150-300 m/min, and the feed rate is controlled at 0.1-0.3 mm/rev to reduce the accumulation of chips.
• Use efficient cooling and lubricating fluid to ensure good cooling and lubrication of the cutting zone to prevent chip adhesion.

Improve the Finish of C17200 Beryllium Copper Alloy Workpiece

Copper C17200 is a beryllium copper alloy with high strength and hardness, but it is easy to generate heat accumulation during cutting, resulting in surface hardening and milling cutter tool wear. In addition, built-up edge is easily formed during cutting, affecting the finish.

How to Improve the Finish of C17200 Beryllium Copper Alloy Workpiece

• Choose coated end mills with good wear resistance, such as TiAlN coated milling cutters, to reduce the formation of built-up edge and cutting tool wear.
• Control the cutting speed at 100-200 m/min and the feed rate at 0.05-0.2 mm/rev to reduce heat accumulation.
• Use high-pressure coolant to ensure sufficient cooling of the cutting area to prevent surface hardening and built-up edge.

Improve the Finish of C17510 Beryllium Copper Alloy Workpiece

Beryllium copper C17510 has high strength, hardness and conductivity, but it is easy to generate high cutting forces and built-up edge during cutting, affecting the surface finish. In addition, heat accumulation is easy to occur during the cutting process, causing the end mill tool to wear quickly.

How to Improve the Finish of C17510 Beryllium Copper Alloy Workpiece

• Use high-hardness ceramic end mill tools or CBN end mill tools, and choose coated milling tools with good anti-adhesion performance, such as TiCN coating, to reduce tool wear and built-up edge.
• The cutting speed is controlled at 70-140 m/min and the feed rate is controlled at 0.05-0.2 mm/rev to reduce heat accumulation and built-up edge.
• Use high-efficiency coolant to ensure sufficient cooling and lubrication of the cutting area to prevent high temperature from causing tool wear and the formation of built-up edge.

Improve the Finish of C18200 Chrome Zirconium Copper Alloy Workpieces

Copper C18200 is a chrome-zirconium-copper alloy with high strength and wear resistance, but it is easy to produce built-up edge during cutting, resulting in a decrease in surface finish. At the same time, high-hardness materials are prone to end mill tool wear.

How to Improve the Finish of C18200 Chrome Zirconium Copper Alloy Workpieces

• Use high-hardness carbide end mills and select coated milling cutters with good anti-adhesion properties, such as TiCN coatings.
• Control the cutting speed at 80-150 m/min and the feed rate at 0.05-0.2 mm/rev to reduce built-up edge and cutting tool wear.
• Use high-efficiency cooling and lubricating fluid to ensure good cooling and lubrication of the cutting area to reduce built-up edge and tool wear.

Improve the Finish of C26000 Brass Workpieces

Brass C26000 has high strength and ductility, but it is easy to produce chip adhesion and built-up edge during cutting, resulting in a decrease in surface finish. In addition, vibration and end mill tool wear are prone to occur during cutting.

How to Improve the Finish of C26000 Brass Workpieces

• Use sharp carbide end mills and select coated tools with good anti-adhesion properties, such as TiAlN coatings.
• The cutting speed is controlled at 150-300 m/min, and the feed rate is controlled at 0.1-0.25 mm/rev to reduce chip adhesion and built-up edge.
• Use efficient cooling and lubricating fluid to ensure good cooling and lubrication of the cutting area, reduce vibration and tool wear.

Improve the Finish of C28000 Brass Workpieces

Brass C28000 has good mechanical properties and corrosion resistance, but it is easy to produce chip adhesion and built-up edge during cutting, affecting the surface finish. In addition, end mill tool wear and vibration are prone to occur during cutting.

How to Improve the Finish of C28000 Brass Workpieces

• Use sharp carbide end mill tools and choose coated tools such as TiCN coating to reduce chip adhesion and built-up edge.
• The cutting speed is controlled at 150-300 m/min, and the feed rate is controlled at 0.1-0.25 mm/rev to reduce tool wear and vibration.
• Use efficient cooling and lubricating fluid to ensure sufficient cooling and lubrication of the cutting area to prevent tool wear and chip adhesion.

Improve the Finish of C36000 Brass Workpieces

Brass C36000 has good machinability and corrosion resistance, but it is easy to produce chip adhesion and built-up edge during cutting, affecting the surface finish. In addition, vibration is easy to generate during the cutting process, affecting the surface quality.

How to Improve the Finish of C36000 Brass Workpieces

• Use sharp carbide end mills and choose coated milling cutters with good anti-adhesion performance, such as TiN coatings.
• The cutting speed is controlled at 200-400 m/min and the feed rate is controlled at 0.1-0.3 mm/rev to reduce chip adhesion and built-up edge.
• Use high-efficiency cooling and lubricating fluid to ensure sufficient cooling and lubrication of the cutting area to reduce vibration and surface defects.