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More about End Mills
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The end milling process uses a rotating cutting tool, known as an end mill, to remove chips from a work piece. In end milling, the cutting tool axis is perpendicular to the work surface, although it is sometimes adjusted to machine unusual shapes. The outer part of the cutter performs the majority of the machining as the work piece is fed past its rotating teeth. The cut length, metal removal rate, and cut depth are determined by a number of variables, which must be calculated before the operation begins.
A wide variety of milling machines are used for milling applications, most falling into four main categories. There are column-and-knee type, bed type, planer type and special milling machines. Planer milling machines are used almost exclusively for large work pieces, and within each type, there are a number of subtypes. For example, both simplex and universal milling machines can be deemed bed type machines.
In addition, milling cutters come in a variety of shapes, only some of which are suitable for end milling operations. Among the milling cutters available are plain, interlocking slotting, corner rounding, four fluted end, dove tail and form milling cutters. End mills are cutters with a straight or tapered shank that has a circular band of cutting teeth. There are also a number of types of end mills available, including shell, plain and hollow end mills. Shell end mills do not have a shank, but have a recessed center in the face that allows it to be mounted on a shank or stub arbor. Hollow end mills are used to create short cylinders, and have teeth on the end of a hollow cutting tube. Other end mills have disposable tips, which can be replaced after they become worn.
Regular shapes machined by end mills include profiles, faces and similar surfaces. The material being milled will help determine the type of tool used; the majority of end mills are made from tungsten carbide, which provides an extremely hard cutting surface. These end mills are typically coated to minimize wear and assist in the cutting process.
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