Numerous parts make up an end mill that might be described in a tool description. It's critical to comprehend how each component can affect tool selection and how even seemingly insignificant decisions can have a significant impact on the tool's performance. In this article, we'll go over an end mill's anatomy to help you understand end milling better.
End Mills are used in the processes of milling, profiling, contouring, slotting, counterboring, drilling, and reaming to create shapes and holes in a material. They may be used to cut a range of materials in various directions since they are built with cutting teeth on the face and edge of the body. Here we are going to discuss the anatomy of an end mill:
The cutting end of the tool's profile is its form. Usually, there are three choices: ball, corner radius, and square.
When selecting a tool for their work, machinists frequently check the cutter diameter first. This measurement describes the circumference of the idealized circle the tool's cutting blades create as it rotates.
The width of the tool's shank, which is retained by the tool holder and is not used for cutting, is known as the shank diameter. When selecting a tool, it's crucial to consider this measurement to make sure the shank is the proper size for the holder being used. To fit well into any holder, shank diameters need to have close tolerances and concentricity.
Since overall length is only the distance between the tool's two axial ends, it is simple to understand. This is contrasted with the length of cut (LOC), which excludes the tool's shank and measures the practical cutting depth in the axial direction only.
The length of the tool's cutting portion is known as the flute length of an end mill. It is calculated from the top of the tool's cutting end to the beginning of the necked part. In deep-pocket milling operations, the neck relief creates room for chip drainage and keeps the shank from rubbing.
The angle produced between a tool's center line and a vertical line tangent along its cutting edge is used to calculate a tool's helix angle. For finishing, a larger helix angle (such as 45°) circles around the tool more quickly and produces an aggressive cut. For the harshest roughing tasks, a lower helix angle (35°) wraps more slowly and would provide a more robust cutting edge.
A tool capable of basic roughing, slotting, and finishing operations with good results would have a medium helix angle of 40°. In some high-performance tooling, chatter is reduced by utilizing a helix angle that differs slightly between flutes. A variable helix helps reduce chatter by dampening reverberations that would otherwise cause uneven timing between cuts.
The part of the end mill that is the simplest to identify is the flute. The tool's deep spiraling grooves that facilitate chip production and evacuation are those grooves. To put it simply, flutes are the component of the end mill's anatomy that allows it to cut on its edge.
Flute count is a factor that needs to be taken into account when choosing a tool, which we have already addressed in great detail. The flute valley, or the area between cutting edges, is typically bigger the lower the flute count.
The strength of the tool is impacted by this void, but it also permits larger chips and deeper cuts, which are perfect for soft or gooey materials like aluminum. Tool strength becomes more important when cutting tougher materials like steel, therefore higher flute counts are frequently employed.
The two primary components utilized to make cutting tools are HSS and carbide.
So, the final word is this. If you want to get the most out of your investment, use end mills with a carbide coating since they are more durable and have a longer tool life.
By choosing the appropriate tools, such as end milling, for your task, you can increase the caliber of your work and lessen the amount of hand-finishing that is required. End mills can be divided into groups according to the kinds of tools attached to them, the number of flutes, the helix angle, the composition of the material, and even the kind of coating. Parameters can change based on the mill's intended use and the characteristics of the treated metal.
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