End mill


An end mill is a type of milling cutter, a cutting tool used in industrial milling applications. It is distinguished from the drill bit in its application, geometry, and manufacture. While a drill bit can only cut in the axial direction, most milling bits can cut in the radial direction. Not all mills can cut axially; those designed to cut axially are known as end mills.
End mills are used in milling applications such as profile milling, tracer milling, face milling, and plunging.

Types

Several broad categories of end- and face-milling tools exist, such as center-cutting versus non-center-cutting ; and categorization by number of flutes; by helix angle; by material; and by coating material. Each category may be further divided by specific application and special geometry.
A very popular helix angle, especially for general cutting metal materials, is 30°. For finishing end mills, it is common to see more tight spiral, with helix angles 45° or 60°. Straight flute end mills are used in special applications, like milling plastics or composites of epoxy and glass. Straight flute end mills were also used historically for metal cutting before invention of helical flute end mill by Carl A. Bergstrom of Weldon Tool Company in 1918.
There exist end mills with variable flute helix or pseudo random helix angle, and discontinuous flute geometries, to help break material into smaller pieces while cutting and reduce tool engagement on big cuts. Some modern designs also include small features like a chipbreaker. While more expensive, due to more complex design and manufacturing process, such end mills can last longer due to less wear and improve productivity in high speed machining applications.
It is becoming increasingly common for traditional solid end mills to be replaced by more cost-effective inserted cutting tools.
End mills are sold in both imperial and metric shank and cutting diameters. In the USA, metric is readily available, but it is only used in some machine shops and not others; in Canada, due to the country's proximity to the US, much the same is true. In Asia and Europe, metric diameters are standard.

Geometry and tools

A variety of grooves, slots, and pockets in the work-piece may be produced from a variety of tool bits. Common tool bit types are: square end cutters, ball end cutters, t-slot cutters, and shell mills. Square end cutters can mill square slots, pockets, and edges. Ball end cutters mill radiused slots or fillets. T-slot cutters mill exactly that: T-shaped slots. Shell end cutters are used for large flat surfaces and for angle cuts. There are variations of these tool types as well.
There are four critical angles of each cutting tool: end cutting edge angle, axial relief angle, radial relief angle, and radial rake angle.
Depending on the material being milled, and what task should be performed, different tool types and geometry may be used. For instance, when milling a material like aluminium, it may be advantageous to use a tool with very deep, polished flutes, a very sharp cutting edge and high rake angles. When machining a tough material such as stainless steel, however, shallow flutes and a squared-off cutting edge will optimize material removal and tool life.
A wide variety of materials are used to produce the cutting tools. Carbide inserts are the most common because they are good for high production milling. High speed steel is commonly used when a special tool shape is needed, not usually used for high production processes. Ceramics inserts are typically used in high speed machining with high production. Diamond inserts are typically used on products that require tight tolerances, typically consisting of high surface qualities. In the early 90s, use of coatings to reduce wear and friction became more common. Most of these coatings are referred to by their chemical composition, such as:
coated end mills, coated using the cathodic arc deposition technique
Advances in end mill coatings are being made, however, with coatings such as Amorphous Diamond and nanocomposite PVD coatings beginning to be seen at high-end shops.
End mills are typically made on CNC tool and cutter grinder machines under high-pressure lubricants such as water, water-soluble oil, and high-flashpoint oil. Grinding inside the machine is accomplished with abrasive wheels mounted on a spindle. Depending on what material is being ground, these wheels are made with industrial diamond, cubic boron nitride, and other materials, set in a bond.