Milling cutters

- Jun 28, 2018 -

Many different types of cutting tools are used in the milling process. Milling cutters such as endmills may have cutting surfaces across their entire end surface, so that they can be drilled into the workpiece (plunging). Milling cutters may also have extended cutting surfaces on their sides to allow for peripheral milling. Tools optimized for face milling tend to have only small cutters at their end corners.

The cutting surfaces of a milling cutter are generally made of a hard and temperature-resistant material, so that they wear slowly. A low cost cutter may have surfaces made of high speed steel. More expensive but slower-wearing materials include cemented carbide. Thin film coatings may be applied to decrease friction or further increase hardness.

They are cutting tools typically used in milling machines or machining centres to perform milling operations (and occasionally in other machine tools). They remove material by their movement within the machine (e.g., a ball nose mill) or directly from the cutter's shape (e.g., a form tool such as a hobbing cutter).

A diagram of revolution ridges on a surface milled by the side of the cutter, showing the position of the cutter for each cutting pass and how it corresponds with the ridges (cutter rotation axis is perpendicular to image plane)

As material passes through the cutting area of a milling machine, the blades of the cutter take swarfs of material at regular intervals. Surfaces cut by the side of the cutter (as in peripheral milling) therefore always contain regular ridges. The distance between ridges and the height of the ridges depend on the feed rate, number of cutting surfaces, the cutter diameter.[4] With a narrow cutter and rapid feed rate, these revolution ridges can be significant variations in the surface finish.