Milling cutters are rotary cutting tools that exist as part of the milling machines or machining centers to carry out processes like face milling, end milling, slotting, and profiling. They have the cutting edges (the teeth) on their periphery or face, which enable them to remove material from the workpiece. Milling cutters are of different shapes, sizes, and materials, each designed for the purpose.
Types of Milling Cutters
End Mill Cutters – Used to profile, slot, and contour. End mill cutters are sold in flat, ball nose, and corner radius designs.
Face Mill Cutters – Used to machine surfaces with great efficiency while imparting a smooth finish to large surfaces.
Slab Milling Cutters – Wide cutters for use in heavy-duty material removal on flat surfaces.
Hollow Milling Cutters – A hollow or tubular design is used to machine cylindrical surfaces.
Fly Cutters – Single-point cutting tool that provides a smooth finish to flat surfaces.
Gear Cutters – Designed specifically by purpose for gear manufacturing.
T-Slot Cutters – Produces T-shaped slots in machine tables or fixtures.
Types of Materials in Milling Cutters
High-Speed Steel (HSS): Cost-effective materials used for low to medium speeds in machining.
Carbide: Very hard and wear-resistant, which is required in fast machining.
Ceramic & Cermet: Very useful in dry cutting at high temperature with minimal wear.
Coated Tools: Extending tool life and improving performance due to TiN coating, TiAlN coating, DLC, etc.
Milling Cutters Applications
Machining metal parts, wood parts, and plastic parts.
Used to manufacture components in the automotive, aerospace, and mold industries.
Creation of slots, grooves, and profiles.
Finishing surfaces to achieve precise tolerances.
Advantages of Milling Cutters
High efficiency: Multiple cutting edges allow for faster removal of material.
Precision machining: Can achieve tight tolerances and accurate dimensions.
It can be used on various materials and shapes.
Surface finish can be smooth and uniform.
Durability: Advanced materials and coatings give better services.
Maintenance for Milling Cutters
Regularly check the cutters for any wear or damage.
Reasonable cutting speeds and feeds have to be used.
Ensure proper lubrication and/or coolant use.
Store cutters in a dry, safe environment.
Resharpening tools where necessary will maintain their efficiency.
FAQs about Milling Cutters
Q1: What is the difference between an end mill and a face mill cutter?
A: End mills cut with their sides and tips, thus being the most suitable to use for profiling and slotting. Face mills, on the other hand, cut mainly at the tips of their inserts and are best used for machining large flat surfaces.
Q2: How do I choose the right milling cutter for my work?
A: You need to take into account the material of the workpiece, specified surface finish, depth of cut, and speed of machining. Carbide cutters are favored for hard materials, whilst HSS is for softer ones.
Q3: Are milling cutters resharpened?
A: Yes, resharpening is permitted for prolonging the life of HSS and carbide milling cutters, if not excessively worn out or damaged.
Q4: Why do coated milling cutters work better?
A: Coating with materials such as TiN or TiAlN reduces the coefficient of friction on the milling cutter, improves the wear-resistant properties, and permits an increase in the cutting speed, thus optimizing the overall performance.
Q5: What speed is best suited for the milling cutter?
A: The best speed varies with the cutter material, diameter, and workpiece material. For best results, refer to the manufacturer’s speed and feed charts.