End Milling Process: Techniques and Types

CNC铣削 is essential in modern manufacturing, with end milling being a widely utilized process. This article explores the key concepts of end milling, including its methods and purposes. Furthermore, we will cover the different types of end mills, their sizes, and the advantages and disadvantages of each. By comparing end milling to other milling operations, you’ll gain insights into its unique applications.

What is End Milling?

End milling is a versatile machining process that employs a rotating cutting tool called an end mill to remove material from a workpiece. This technique allows for the creation of complex shapes and features, such as profiles, contours, and machine slots. As such, it’s suitable for a variety of materials, including metals, plastics, and composites.

Furthermore, the end mill features cutting edges on both the tip and periphery, enabling it to perform both peripheral and end cutting effectively. Its helical cutting edges are designed to minimize impact during initial engagement with the workpiece, which enhances cutting efficiency and accuracy.

How to Perform End Mill?

To effectively perform end milling, follow these steps to ensure a successful machining process:

1. Set Up the Workpiece:

Before starting end milling, secure the workpiece on the machine using holding devices like vises and clamps. This ensures the part is firmly in place, minimizing unnecessary vibrations during the milling process.

2. Choose the Milling Tool:

Next, select the appropriate end mill based on the material you intend to cut. For steel, a tough carbide end mill is recommended, while high-speed steel end mills work well for softer materials like aluminum. Additionally, consider the cutting depth required. A shorter end mill is often better for shallow cuts, as it minimizes vibration and improves surface finish.

3. Set the Feed Rate and Speed:

After selecting the tool, adjust the cutting speed and feed rate according to the recommended parameters for the material. The speed of the cut directly impacts the quality of the surface finish, so selecting optimal settings is crucial.

4. Determine Correct Cutting Depth:

In addition, cutting depth measures how much material the end mill removes with each pass. Best practices recommend keeping the cutting depth to no more than half of the end mill’s diameter per pass. By following these guidelines, you can prevent the tool from overheating and breaking.

5. Test the End Milling Process:

Before proceeding with the full operation, conduct a test cut on a small section of the workpiece to ensure everything functions properly. Then, make any necessary adjustments based on the results of this preliminary test.

6. Perform the Milling Process:

Activate the coolant to prevent overheating of both the workpiece and the end mill, which will enhance cutting performance and extend tool life.

7. Monitor the Cutting Process:

As you cut, keep an eye on the machine for any irregularities, such as vibrations or unusual noises, and adjust as necessary.

8. Inspect the Workpiece:

After milling, check the dimensions and surface finish to ensure they meet specifications.

9. Clean Up:

Finally, clear away chips and debris from the work area, properly store the end mill, and clean the machine to maintain its condition. This ensures the machine remains in optimal working order for future projects.

Types of End Mills

To effectively utilize end milling in various applications, it’s important to understand the different types of end mills available. Each type is designed for specific purposes, enhancing versatility and precision in machining. Here are some common types of end mills:

1. Square End Mill: Features a flat cutting edge, ideal for producing flat surfaces, slots, and precise square corners.
2. 球头立铣刀: Has a rounded tip, perfect for creating curved surfaces, contours, and intricate shapes.
3. Chamfer End Mill: Designed with an angled cutting edge to create bevels or chamfers on the edges of the workpiece.
4. Tapered End Mill: Tapers down to a point, allowing for angled cuts and the creation of tapered features.
5. Corner Radius End Mill: Includes a rounded corner, which reduces tool wear and improves surface finish on corners.
6. Roughing End Mill: Specifically designed for aggressive material removal, often with serrated edges to break up chips.
7. High-Feed End Mill: Features a design that allows for high chip loads, enabling aggressive cutting with higher feed rates.
8. Indexable End Mill: Uses replaceable cutting inserts, making it cost-effective for prolonged use and easy maintenance.
9. Multi-Flute End Mill: Contains more than two flutes, providing increased feed rates and improved surface finishes.
10. Keyway End Mill: Specifically designed to cut keyways, featuring a flat bottom and precise dimensions for fitting keys in shafts.
11. Roughing and Finishing End Mills: Combines roughing and finishing capabilities in a single tool, allowing for effective material removal followed by a smooth finish.
12. Corner Rounding End Mill: Designed to create rounded corners on workpieces, enhancing aesthetics and reducing sharp edges.
13. Drill Mill: Combines drilling and milling functions, allowing for drilling holes and milling flat surfaces with the same tool.
14. Specialty End Mills: Tailored for specific applications, such as engraving or contouring, to meet unique machining needs.

End Mill Sizes

Selecting the right end mill size is essential for optimal machining results. End mills typically range from 0.5 mm to over 25 mm in diameter, impacting cut size and tool strength. The cutting flute length usually varies from 1.5 to 3 times the diameter, while overall lengths span 50 mm to 150 mm. Flute counts range from 2 to 8, affecting chip removal and surface finish. Common shank sizes include 3 mm, 6 mm, 1/4 inch, and 1/2 inch, which must match the machine spindle. Additionally, tolerances and custom sizes are available for specific needs. Understanding these factors ensures effective tool selection and enhances machining efficiency.

Below is the standard end mill size chart:

Fractional	Decimal	Fractional	Decimal
1/64	0.0156	5/16	0.3125
1/32	0.0313	21/64	0.3281
3/64	0.0469	11/32	0.3438
1/16	0.0625	23/64	0.3596
5/64	0.0781	3/8	0.3750
3/32	0.0938	25/64	0.3906
7/64	0.1094	13/32	0.4063
1/8	0.1250	27/64	0.4219
9/64	0.1406	7/16	0.4375
5/32	0.1563	29/64	0.4531
11/64	0.1719	15/32	0.4688
3/16	0.1875	31/64	0.4844
13/64	0.2031	1/2	0.5000
7/32	0.2188	9/16	0.5625
15/64	0.2344	5/8	0.6250
1/4	0.2500	11/16	0.6875
17/64	0.2656	3/4	0.7500
9/32	0.2813	7/8	0.8750
19/64	0.2969	1	1.0000

Pros and Cons of End Milling

Pros:

• Versatility: End milling can create complex shapes, contours, and features in various materials, making it suitable for diverse applications.
• Precision: This process allows for high accuracy and tight tolerances, essential for precision engineering.
• Multiple Cutting Types: It can perform both peripheral and end cutting, enhancing its functionality in a single operation.
• Surface Finish: End milling can achieve superior surface finishes, which is important for aesthetic and functional requirements.
• CNC Compatibility: Easily integrated with CNC technology, it offers automated control over cutting parameters, improving efficiency and repeatability.

缺点:

• Tool Wear: End mills can wear down quickly, especially when used on harder materials, leading to increased costs for tool replacement.
• Limited Depth of Cut: The maximum depth of cut is often restricted by the tool’s length, which may require multiple passes for deeper features.
• Chip Removal: In certain applications, effective chip removal can be challenging, potentially impacting cutting efficiency and tool performance.
• Setup Time: Initial setup and alignment can be time-consuming, particularly in CNC applications, affecting overall production time.
• Cost: High-quality end mills and CNC machinery can represent a significant investment, impacting budget constraints for some operations.

Applications of End 米ill parts

End mills are integral to a wide range of manufacturing processes due to their versatility and precision. Here are some of the most significant applications:

• Machining Complex Shapes: End mills excel in creating intricate shapes and profiles across various materials, making them essential for custom parts in diverse industries.
• Die and Mold Production: They are crucial for producing die cavities and molds used in manufacturing processes like injection molding and casting, ensuring high accuracy in final products.
• Slot and Pocket Milling: End mills are commonly used to create slots, pockets, and keyways, which are vital for the assembly and functionality of mechanical components.
• Surface Finishing: These tools are employed in finishing operations to achieve smooth surface finishes on machined parts, which is critical for both aesthetics and performance.
• Automotive and Aerospace Industries: End mills play a key role in producing precision parts for automotive and aerospace applications, where high-quality standards are mandatory.

Milling Operations Comparison

1. End Milling vs. Drilling

End milling creates complex shapes and contours while drilling primarily produces holes. In addition, end mills feature cutting edges on both the tip and sides for versatile cutting, whereas drills have a pointed tip specifically for hole creation. Consequently, end milling is ideal for detailed profiles, while drilling is best for straightforward hole-making tasks.

2. End Milling vs. 平面铣削

End milling uses the end of the tool for vertical and angled cuts, enabling intricate shapes, while plain milling employs the flat sides of the cutter for horizontal cuts, generally used for flat surfaces. Furthermore, end mills have varied flute designs for complex profiles, whereas plain milling cutters are simpler, and designed for straightforward operations.

3. End Milling vs. Face Milling

End milling cuts with the end and peripheral edges of the tool, ideal for intricate profiles and contours. Face milling focuses on cutting across the surface of the workpiece, producing flat areas and larger surfaces. End milling allows for various angles and detailed features, while face milling operates mainly in a horizontal plane, providing smooth finishes on flat surfaces.

4. End Milling vs. Side Milling

End milling utilizes the end of the tool for axial cuts, allowing for detailed profiles and complex shapes. Side milling, on the other hand, uses the side edges of the cutter for lateral cuts, creating flat surfaces. While end milling excels at intricate contours, side milling is more effective for wider cuts and slots, making it suitable for broader applications.

Various Milling Operations at Runsom

在 瑞盛精密科技有限公司, we offer a wide range of milling operations to meet diverse manufacturing needs. Our capabilities include CNC milling for precision and repeatability, end milling for intricate shapes, and face milling for flat surfaces. We also specialize in slot milling for essential slots and keyways, as well as drilling and tapping for efficient hole-making and threading. Additionally, our profiling operation creates complex contours, while roughing and finishing techniques ensure quick material removal and quality surface finishes. This diverse range of milling services positions Runsom as a reliable partner for all your machining needs.

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