End milling cutters are tools used on milling machines to perform a variety of machining operations. Such as slotting, chamfering, contouring, ramping, and plunging. Different types of end mills are designed based on the material being machined, the intended operation, and the desired shape or profile. They are designed to meet specific machining needs and ensure the best cutting results.
Flat Bottom Milling Cutters and Slotting Cutters
Flat-bottom milling cutters and slotting cutter end mills are available in a variety of sizes, materials, and coatings. To accommodate different workpiece materials, cutting conditions, and machining requirements. Choosing the right tool depends on factors such as the desired slot size, material hardness, machine speed, and required surface finish.
Flat Bottom/Sharp Angle Mills
Versatile and can be used for both roughing and finishing operations. Milling cutters, which typically have 4 or more edges, can create flat-bottomed slots, pocket slots, and flat faces. However, due to their sharp angles, they may leave small marks or steps in the corners of machined features.
Flat Bottom/Sharp Angle Slot Mills
Particularly useful when machining closed-end slots. Because they have center cutting teeth, they are capable of plunging. Typically with 1-3 edges, they come in a variety of widths and can create slots of different sizes. Slot drills are commonly used on milling machines to produce keyways, grooves, and other similar applications.
Ball Nose End Mill
A ball nose milling cutter is a milling tool with a spherical cutting edge. It is called a “ball nose” because the cutting edge resembles the shape of a ball. The milling cutter has a rounded nose portion that gradually transitions from the cutting edge to the cutter body.
Ball nose end mill bits are primarily used to create contoured surfaces, three-dimensional shapes, and chiseled features on a workpiece. They are also used to create chamfer radii. Some technical drawings will call for chamfer radii because they are stronger than right angles. The ball nose shaped cutting edge allows for smooth and consistent material removal. This is especially true when machining curves or irregular surfaces. The spherical shape of the cutting edge enables the milling cutter to follow the contour of the workpiece. This results in a smooth transition and improved surface finish.
Corner Radius Milling Cutter
A corner radius end mill is a milling cutter with a rounded cutting edge that forms a specific radius. Unlike square milling cutters or ball nose milling cutters. which have a pointed corner or spherical shape, respectively, a corner radius milling cutter has a semicircle at the corner where the cutting edges meet. Some people refer to these cutters as bull’s mouth cutters, and needless to say, the semi-rounded corners strengthen the cutting edge, preventing chipping, thereby extending the life of the cutter.
Corner Rounding Milling Cutter
A corner rounding end mill is a milling cutter used to create external fillets on a workpiece. It is cylindrical in shape and has a rounded cutting edge that gradually blends into the adjacent surface. This cutting edge is responsible for removing material and forming a smooth corner. When selecting a radius milling cutter, factors such as the required radius size, workpiece material, cutting conditions, and machine tool capabilities should be considered to achieve the desired fillet effect efficiently and accurately.
Chamfer Milling Cutter
Also known as a chamfer end mill or chamfer milling cutter, is a specialized type of milling tool used to create chamfered edges or beveled features on a workpiece. It is specially designed to chamfer and cut, forming an inclined edge or bevel.
Chamfer milling cutter bits are widely used in applications where chamfers or bevels are required, such as when preparing weld edges, improving part aesthetics, or creating chamfered features on machined components. Using a chamfer milling cutter can eliminate the need for manual deburring, saving time and money. The choice of chamfer milling cutter depends on factors such as the required chamfer angle, material properties, cutting conditions, and machine capabilities.
Dovetail Milling Cutter
A dovetail milling cutter is a specialized milling tool used to create dovetail slots or general slots with precise angles. It is named after the dovetail joint, known for its interlocking wedge shape.
Dovetail milling cutters are essential tools for creating dovetail joints or mating surfaces that require precise interlocking profiles. Selecting the appropriate dovetail milling cutter depends on factors such as the required dovetail angle, material properties, cutting conditions, and specific application requirements.
T-Slot/Half Round
A T-Slot milling cutter, also known as a Woodruff milling cutter, is a specialized milling cutter used to create a T-slot or keyway in a workpiece. It is named after its inventor, William Woodruff, who invented the Woodruff key and related cutters.
T-Slot/Woodruff Geometry: T-Slot milling cutters have a specific shape with a cylindrical body and a unique cutting edge profile. The cutting edge has a T-shaped groove that matches the dimensions of the desired T-slot or Woodruff keyway. The T-slot design allows a T-nut or other fastener to be inserted into the slot.
Roughing End Mill
A roughing end mill, also known as a roughing mill, is a milling cutter designed specifically for the quick and efficient removal of large amounts of material. It is primarily used for roughing or preliminary machining operations where the goal is to remove large pieces of material rather than to achieve a fine finish.
Roughing end mills are particularly useful when machining large workpieces, removing excess material, or preparing workpieces for finishing operations. They are capable of processing tough materials such as steel, cast iron, and other high-strength alloys.
When selecting a roughing end mill, factors such as material type, desired material removal rate, cutting conditions, and machine tool capabilities should be considered. To achieve an efficient and effective roughing operation.
Short Neck/Long Neck/Wing Rib Milling Cutters
A short neck milling cutter is a special type of milling tool characterized by a reduced neck diameter relative to the cutting diameter. It is designed with a shorter flute length or a narrower shank diameter than a standard milling cutter. This short neck design allows for improved tool stability, increased reach, and enhanced performance in certain machining applications. The short neck provides clearance in shoulder milling and pocket milling applications, and it stops shank friction when machining beyond the slot length.
A long neck milling cutter or extended slot milling cutter is a special type of milling cutter designed with an extended neck or slot length compared to a standard milling cutter. It has a longer neck that allows for deeper reach and access to hard-to-reach areas of the workpiece. A protrusion milling cutter is a milling tool specifically designed for machining protrusions or thin walls on a workpiece. It is specifically designed to create precise and consistent features, such as wing ribs, etc., with a high degree of accuracy and efficiency.
Tapered Neck Milling Cutter
A tapered milling cutter, also known as a tapered shank milling cutter or tapered neck milling cutter, is a specialized type of milling cutter with a tapered shank or neck portion. This design increases the rigidity of the tool, improves accessibility, and increases performance in specific milling operations.
Tapered neck milling cutters are commonly used in a variety of machining operations, including contouring, slotting, and profiling. They are suitable for machining materials such as metals, plastics, composites, and more in industries such as aerospace, automotive, mold making, and general machining. Tapered necks are also known as barrel cutters.
Side Milling Cutter/Face Milling Cutter
Side and side end mill bit is a type of milling cutter mainly used for machining workpiece planes, slots, sides, flat surface contours. It is a versatile tool that is capable of performing multiple cutting operations in one pass. Selecting the right milling cutter is essential to achieve the accuracy, surface finish, productivity and tool life of the machining task.
The selection of milling cutter depends on factors such as the material being machined, the type of operation, the desired profile, and the overall machining strategy.
When using side and face milling cutters, it is important to consider factors such as cutting parameters, workpiece material, tool path strategy and machine tool capabilities. To achieve the desired machining results and tool clamping force. Proper tool selection and setup are essential for efficient and accurate milling operations using side and face milling cutters.
Selecting the right milling cutter is essential to achieve the accuracy, surface finish, productivity and tool life of the machining task.
The selection of milling cutter depends on factors such as the material being machined, the type of operation, the desired profile, and the overall machining strategy.
