Manufacturing Processes

End Milling It is the combination of peripheral and face milling operations. The cutter has teeth both on its periphery and its end. If the direction of helix of the cutter is same as the direction of rotation of it, the end cutting edges are used only to remove metal. If the direction of helix and the direction of rotation of the cutter are opposite to each other, the peripheral cutting edges are used to remove metal. An end mill is a tool used on a milling machine. A milling machine is a machine found in a metal working shop that is used to remove material from a metal block to make it into a finished part. An end mill is one of the tools used on the milling machine to make a particular type of cut.End mills come in single ended and double ended varieties. A single ended end mill has only one useful working end; the other end is just a smooth shank for holding the end mill in the tooling holder on the milling machine. A double ended end mill has two useful working ends. When one end becomes dull and no longer useful, the end mill can be installed such that the opposite end can be used.

End mills are made of carbide steels, with the cutting surfaces sometimes made entirely of carbides. It is also common for end mills to be coated with a very thin layer of titanium nitrate. Titanium nitrate is a gold colored coating that prevents the metal chips being removed from the part from sticking to the end mill, reducing its life and the quality of the cut. End mills come in a wide variety of shapes and sizes. To those unfamiliar with metal machining, an end mill will look like an odd drill bit. While an end mill can be used to drill a hole, its function is much larger than that. In many ways, a milling machine with an end mill is very similar to a router in wood working. An end mill can be used to cut blind holes or grooves, bevel edges, cut a flat edge, and make holes in a block of material. An end mill can also be used to make bearing raceways and cylinders. You cannot make a square hole with an end mill, but you can make a square post. An end mill coupled with a milling machine is possibly the most versatile machine in the shop. End mills come in a wide variety of shapes and sizes. To those unfamiliar with metal machining, an end mill will look like an odd drill bit. The carbide end mill is one of several

08-ME-33

Manufacturing Processes

types of milling tools that are commonly used. End mills are distinguished from other types because they have cutting teeth at one end as well as on the sides.

End Mill Cutter

Basically, milling cutter is used in machining centers or milling machines. There is a long list of varieties of milling cutters and some of them are Involutes gear cutter, End Mill, Roughing End Mill, Slab mill, Slot drill, Woodruff cutter, Hob, Fly cutter, , Face mill, Dovetail cutter, Hollow mill, Side and face cutter. There are cutting teeth on the sides as well as at one end in the End mill cutter. Generally, end mill cutter is referring as flat bottom cutter. Radiuses cutter (such as torus or bull nose) and rounded cutter (such as ball nosed) also lie in the category of cutter. This type of tool is commonly used in vertical mill. They are made up of carbide or (HSS) high speed steel. The difference in drill bit and end mill cutter is in its geometry, its manufacturing and its application. End mill cutter is used in the milling applications like tracer mile, plunging, profile milling and face milling.

Types/ Uses
This cutter is used on milling machines. A machine which is used in metal working workshop is known as milling machine. Milling machine is proved as very useful to make finished product by removing waste material from the metal block. To make special type of cut, this cutter is used in the milling machine. End mill cutters are available in two types of varieties: 1. Single ended 2. Double ended When one end becomes dull and no longer useful, the end mill can be installed such that the opposite end can be used. End mills are made of carbide steels, with the cutting surfaces

08-ME-33

Manufacturing Processes

sometimes made entirely of carbides. It is also common for end mills to be coated with a very thin layer of titanium nitrate. The carbide end mill is one of several types of milling tools that are commonly used. End mills are distinguished from other types because they have cutting teeth at one end as well as on the sides. There is only one useful working end in single ended end mill cutter, other side of the tool is smooth shank. However, in double ended end mill there are two working ends. When one of the ends of the double ended mill cutter gets obsolete and dull than it is replaced by other end. End mill cutter is usually made up of carbide steel and is coated by a thin layer of the titanium nitrate. End mill cutter is used to cut bevel edges, flat edge, make hole in metal block, grooves or blind holes. These are also very useful to make cylinders and bearing raceways. It is not possible to make square holes with the help of end mill cutter but making square post is possible. The milling machine is versatile if it is coupled with end mill cutter.

Carbide End Mill Cutter

Carbide end mill cutter is a tool which is used for shaping and cutting solid materials. It looks like drill and also works like drill machine. End mill cutter is made up of tungsten carbide, also known as carbide. Carbide is very heavy and tough material which is capable of cutting metal without scratching or breaking. It is one of the commonly used milling tools. Generally, working of this type of cutter depends up on two factors: 1. Type of material which has to cut 2. Type of milling used For example, if the metal is soft such as aluminum then sharp cutting edges with deeper flutes will be best. In the case of cutting hard material such as stainless steel, square cutting edge and shallow flutes will be preferred. Traditionally, end mill was made of high
08-ME-33

Manufacturing Processes

speed steel but now most of the end mill tools are made of carbide. This material is wear resistant as it is highly rigid material. The carbide end mill is one of several types of milling tools that are commonly used. End mills are distinguished from other types because they have cutting teeth at one end as well as on the sides. End mills come in a wide variety of shapes and sizes. To those unfamiliar with metal machining, an end mill will look like an odd drill bit. While an end mill can be used to drill a hole, its function is much larger than that. A single ended end mill has only one useful working end; the other end is just a smooth shank for holding the end mill in the tooling holder on the milling machine. A double ended end mill has two useful working ends. The carbide end mill is one of several types of milling tools that are commonly used. End mills are distinguished from other types because they have cutting teeth at one end as well as on the sides. The cutter in end milling generally rotates on an axis vertical to the work piece. It can be tilted to machine tapered surfaces. Cutting teeth are located on both the end face of the cutter and the periphery of the cutter body.

08-ME-33