Milling Cutter: Definition, Types, Material

Milling is a process of machining where a rotating cutter removes material from a workpiece to produce a desired shape. The cutter used in this process is called a milling cutter, and it comes in different types, shapes, and sizes. In this article, we will discuss in detail the definition, types, and materials used for milling cutters.

Definition of Milling Cutter:

A milling cutter is a rotary tool used to remove material from a workpiece. It is a cutting tool that cuts the workpiece in a circular motion. It attaches to the milling machine spindle, and the workpiece moves against it to produce a desired shape.

Types of Milling Cutters:

1. End Mills: This type of milling cutter has teeth on the end and side, giving it the ability to cut in all directions. End mills come in a variety of shapes and sizes, each designed for a specific application.

2. Face Mills: Face mills have teeth on the periphery and a large flat face on the bottom, making them ideal for creating a flat surface or milling slots.

3. Ball Nosed Cutters: Ball nose cutters have a rounded end and are ideal for 3D machining, contouring, and profiling.

4. T-Slot Cutters: T-Slot cutters have a T-shaped slot on the bottom, making them ideal for milling T-slots in workpieces.

5. Slab Mills: Slab mills have a large diameter and are ideal for milling large surfaces or cutting slots.

6. Keyway Cutters: Keyway cutters are used to cut keyways in workpieces and come in either square or round shapes.

Geometry of Milling Cutters:

The geometry of a milling cutter plays a critical role in its performance. It includes the tooth profile, helix angle, rake angle, clearance angle, and cutting edge angle. The tooth profile determines the chip formation and cutting forces, while the helix angle determines the chip evacuation and tool life. The rake angle determines the cutting force and surface finish, while the clearance angle determines the chip flow and tool life. The cutting edge angle determines the sharpness and wear resistance of the cutter.

Material Used for Milling Cutters:

The material used for milling cutters should have high strength, toughness, hardness, and wear resistance. High-speed steel (HSS) is one of the most commonly used materials for milling cutters. It is a high-carbon steel alloyed with tungsten, molybdenum, and chromium. HSS is capable of cutting at high speeds and temperatures, making it an ideal material for high-speed machining applications.

However, carbide is becoming more and more popular in recent years because of its high hardness, wear resistance and thermal stability.

Conclusion:

In conclusion, milling cutters are essential tools for machining operations. They come in different types, shapes, and sizes, each designed for specific applications. The geometry and material used for milling cutters play a critical role in their performance. High-speed steel and carbide are the most commonly used materials for milling cutters. They offer excellent cutting performance and efficiency, making them ideal for various milling applications.

Therefore, when choosing milling cutters, it is important to consider the type, geometry and material that suits the job at hand.

Keywords: Milling Cutter, End Mills, Face Mills, Ball Nosed Cutters, T-Slot Cutters, Slab Mills, Keyway Cutters, Milling Machine, High-speed steel, carbide, engraving blades.