End mills
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Frequently asked questions
How do I choose 2, 3, 4 or more flutes?
Two-flute cutters have large chip gullets for aluminum and deep slotting. Three flutes are a middle option for high-speed aluminum. Four or more flutes are stiffer, suiting steel and finish profiling; more flutes means smaller gullets and chip packing risk in slotting.
Which materials suit TiAlN, AlCrN and DLC coatings?
TiAlN and AlCrN withstand high heat, suiting steel, stainless and hardened steel in dry or high-speed cutting. DLC and polished uncoated tools resist built-up edge, suiting aluminum and copper. Aluminum-bearing coatings on aluminum workpieces can cause chip welding.
How do I read an end mill spec such as D10 x 22 x 75?
It usually means 10 mm cutting diameter, 22 mm flute length and 75 mm overall length; many makers add shank diameter and corner radius such as R0.5. DIN 6535 HA shanks are plain, HB shanks have a Weldon flat for side-lock holders.
Is climb or conventional milling better for tool life?
On CNC machines without backlash, climb milling produces a chip that starts thick and ends thin, reducing rubbing and heat, so tool life is usually longer. Conventional milling suits manual machines with backlash or workpieces with a hard scale.
Why do carbide end mills chip early?
High runout makes one flute carry most of the load, long stickout causes chatter, and abrupt entry shocks the edge. Use a low-runout holder, minimum stickout, and helical or arc entry to reduce shock.
Can end mills be reground?
Solid carbide end mills can be reground on the end and periphery several times if wear is not too deep, at the cost of a slightly smaller diameter. After regrinding, update the tool offset and recoat if the tool is used on hard materials. Tools with large chips or broken corners are usually not worth regrinding because too much must be removed.
When are ball nose and corner radius end mills used?
Ball nose cutters machine curved 3D surfaces such as molds, but cutting speed at the center is near zero, so tilt the tool or use small stepovers. Corner radius cutters have a small radius at the edge, which is stronger than a sharp corner and produces a wall-to-floor radius. The corner radius must be equal to or smaller than the radius on the drawing.
What is the benefit of variable helix end mills?
A variable helix or unequal flute spacing makes the edges enter the cut at staggered times, breaking up resonant vibration. This reduces chatter and allows deeper cuts in steel and stainless steel. It helps where stickout is long or the workpiece is less rigid.
