These end mills will also provide a better surface finish. If you want to reduce the cutting forces to minimize heat generation and vibration you need to use cutters with a greater helix angle. Your average and mill bit will probably have a helix angle of about 30 degrees. we have seen the helix angle of end mills already. If that number is higher than the required cutting depth, you might consider a necked reach solution. A simple trick is to multiply the cutter diameter by five. Ideally you pick a length that is just long enough to prevent overhang and to ensure a rigid, precise cutting process. The longest contact length required determines the depth of cut needed for your end mill. So before buying and/or mounting a cutter for your cutting job, make sure to choose an appropriate cutter diameter end mill to get a finished part according to the specifications. It also affects the amount of chip removal for side milling operations. The cutter diameter defines the width of the slot that you can create with your end mill. For harder material you need stronger cutting tools with more flutes and smooth (yet not so deep) cuts. If you want to cut deep in materials such as plastics or aluminum then you want fewer of these cutting teeth. Everything above five flutes indicates finisher end mills used for very fine finishes. End Mills can have only one or two but also up to 12 flutes, however two to four flutes are most common. How many Flutes for which applicatons?įlutes are the spiral-shaped cutting edges at one end of the cutter. We are sure that you would like to avoid that. Using the wrong milling cutter will also pretty quickly result in broken tools. Sure, technically you can try to cut any material with the same end mill, but the cutting performance and the finish quality on the workpiece will vary from excellent to inacceptable. For non-ferrous materials such as aluminum you will need different tooling shapes, materials and dimensions than for steel for example. This will narrow down the number of ‘potential candidates’ significantly as certain types of end mills are specifically made for certain metals/materials. So let us take a closer look at the most important aspects that you need to take into consideration.įirst ask yourself what materials you will want to cut with your new end mills set. Once you have answered these and other questions you will have a better understanding of what type of end mill is needed for your applications.
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