Carbide end mills are expensive tools which are an absolute necessity generally in most successful industrial milling applications. Different carbide end mills serve different purposes – finishing, roughing, material-specific applications, and others – and in order to protect your investment as well as get the best from your equipment, it is vital that you employ them correctly. The following tips may help you accomplish that, potentially saving you thousands.
With regards to choosing the right end mill for your project, two flute square end tools are frequently recommended. These mills are center cutting and created specifically for slotting, plunging, and contouring. The wide flute design is perfect for chip evacuation, especially at higher feed rates with heavy peripheral cuts. Even better – the square end will create a clean 90º angle when slotting.
Carbide end mills come in a range of styles, and the amount of flutes can vary around 12. Multi-flute tools can have different purposes, and in order to protect your investment, it is vital that you utilize them appropriately. Many of the most common include:
Three flute styles. These end mills are a good compromise between your chip removal number of a two flute and the effectiveness of carbide corner radius end mill with additional flutes. Like the two flute option, additionally, it offers a square end to have the ultimate surface finish.
Four flute styles. Four flute end mills are especially versatile with regards to milling in materials where chip packing isn’t an issue. These power tools come with an increased core thickness leading to improved size accuracy and much less tool deflection. In addition they provide for minimal chip load.
Six flute styles. The longevity of the six flute option provides increased tool stability, allowing more cutting edges to keep engaged inside the work material. The end result is extended tool life and reduced chipping from the cutting edges.
Variable helix styles. This tapperedend minimizes deflection and reduces vibration. These characteristics ensures superior finish at high stock removal rates.
If you have to develop a perfectly square corner, especially towards the bottom of any channel, a square end mill can be your best solution. A square end cutting feature can produce clean 90 degree angles at the bottom of the cut. Remember though, fewer flutes enable better chip evacuation.
High helix carbide end mills – which might also be termed as high-spiral, shallow wedge, or high helix angle end mills – are a kind of high-performance cutter that is specifically designed for soft materials.
High helix carbide end mills are usually used in combination with aluminum and other non-ferrous materials, mostly because of the positive shearing action as well as the extra cutting edge for wear.
To have the maximum return on your investment and extend the life span of your carbide end mills, a radius ground is a wonderful solution. The weakest point with an end mill will be the sharp corner, so a ground radius in the tips can prevent chipping.
The initial price of aluminum end mill might be high, particularly for high performance and new designs. However, with proper things to consider for the sort of end mill which will are best for your personal application – together with proper set up – the charge will probably be offset by better finishes, greater productivity, and higher production.