KUTMET

End mill

End mills are those tools that have cutting teeth at one end, as well as on the sides. The words end mill are generally used to refer to flat bottomed cutters, but also include rounded cutters They are usually made from and have one or more flutes. They are the most common tool used in a vertical mill.

Flutes / teeth: The flutes of the milling bit are the deep helical grooves running up the cutter, while the sharp blade along the edge of the flute is known as the tooth. The tooth cuts the material, and chips of this material are pulled up the flute by the rotation of the cutter. There is almost always one tooth per flute, but some cutters have two teeth per flute. Often, the words flute and tooth are used interchangeably. Milling cutters may have from one to many teeth, with two, three and four being most common. Typically, the more teeth a cutter has, the more rapidly it can remove material. So, a 4-tooth cutter can remove material at twice the rate of a two-tooth cutter.

Center cutting: Some milling cutters can drill straight down (plunge) through the material, while others cannot. This is because the teeth of some cutters do not go all the way to the centre of the end face. However, these cutters can cut downwards at an angle of 45 degrees or so.

Gold & Black Coating Gold & Black Endmill Tools

Kutmetal (KUTMET) offers solid carbide end mills and indexable milling tools that cover a wide range of applications. Proven for consistency and benchmarked quality, these tools span multifold operations – from profiling and ramping, to slotting, plunging and interpolation. The end mills are currently available in both shorter and longer shank lengths. Our solutions are designed to optimize productivity, performance, and maximize metal removal.

CNC milling services are an integral part of CNC machining and has gained immense traction over the years as it can be used for a wide range of parts. With CNC milling you can achieve high precision and tight tolerances regardless of a complex geometry. These machines used as high-speed milling cutters to shape the object into the desired shape. They are well-known for their ability to work with various metals and plastics, with each having their own physical and chemical properties which may pose challenges. Any CNC milling services provider must know the reaction and interaction of these machines with each of the materials formed. This is an important aspect which this post throws light on.  Also, it highlights how CNC milling excels in working with maximum substrates. So stay tuned.

Commonly Milled Materials

This manufacturing technique works well with a diverse range of materials. Here are some important ones.

Metals: They have been the most popular choice of CNC milling services providers owing to their beneficial features. Also, they are preferred by most OEMs even when some are replaced by plastic. CNC milling has the ability to machine precise parts with tight tolerances, intricate designs, and smooth finishes and this is one reason these parts are used across industries  such as automotive, aerospace, and heavy engineering. Working with metals, including steel, aluminum, brass, copper, and so on may seem easy. However, it requires attention to detail and considerations like cutting speeds, tool selection, and cooling methods. High-speed carbide tools are used to withstand the high demands of metal machining. Cooling and lubrication are crucial to dissipate heat generated during the process. This helps in preventing tool wear and tear, extending tool life.

Plastics: This is another popular choice for CNC milling, offering a delicate touch while maintaining accuracy. CNC parts made of acrylic, nylon, polycarbonate, and more are durable, lightweight, and visually appealing. While machining plastics, it is essential to manage heat generation to prevent warping or melting. Always, thermoplastics are used as they can withstand high temperatures. Proper chip evacuation and lower cutting speeds are significant in maintaining the material’s integrity. In addition to this, higher rake angle tools are used to minimize cutting forces and potential part distortion.

Composites: As the name implies, they are a fusion of different materials to enhance their properties. However, this presents unique challenges for machining techniques. Owing to the beneficial features of composites, such as strength-to-weight ratio, they are preferred in aerospace and sporting goods. Manufacturing with them requires a fine balance between material-specific considerations and achieving the required precision. Thus, advanced tools with diamond coatings are used when working with abrasive composites.

Ceramics: They are known for their electrical insulation, extreme hardness, and high-temperature resistance properties. CNC milling machines can achieve cutting through tough and abrasive materials like these. While they can be challenging to machine as they are just as brittle, they find use across industries, including aerospace and medical.

This section has covered the commonly CNC milled materials in detail. While material selection holds a great significance in CNC milling, it is equally important to pay attention to the tooling for CNC milling. The next section explains this aspect.

Essential Tooling for CNC Milling

The selection of cutting tools is crucial for successful CNC milling to get the best output. The following are some essential tools to consider for milling.

End Mills: They are commonly used for several milling operations from slotting to contouring. They are available in different sizes and shapes to accommodate multiple milling tasks.

Drills: These tools are mainly used for creating holes. There are different types of drills such as twist, center, and more. The size of the hole and accuracy are two important requisites when choosing drills for your application.

Face Mills: They are ideal for large surfaces. They remove material from the workpiece’s face using multiple cutting edges.

Carbide Inserts: They are replaceable and mounted on milling tools. Carbide inserts extend the tool life and allow for efficient machining.