Ive never done any 5 axis(dream of mine...sigh...) but I've heard that if you must use a ball nose and have 5 axis you should tilt the cutter as to not use the tip.

While the image shows the tool being tilted if you machine a slope in a 3-axis setup then you are getting the same effect

A friend of mine experienced in surfacing was telling me that 2 flute endmills are the only ones that really cut all the way down to the center. I was looking at some 3 and 4 flute ball endmills, and sure enough, I see the relief. Can a 3 or 4 flute be used in the rough surfacing (or any op for that matter) at all, and how do I know the limits for speeds and feeds because of the small section of flute that is essentially not cutting?

I only use a ball nose if I have a feature that requires it, for surfacing I rather use a bull nose or even flat sometimes.  For roughing you're going to go a lot faster with a bull or flat, the ball nose hates to be buried, you're using a lot more surface area when you rough with a ball.

Consider factors such as material, cutting diameter, flute count, coatings, and cutting speed and feed rate when selecting an end mill. By taking the time to choose the right end mill for the job, you can ensure efficient cutting and a high-quality finish.

And yes basically you have zero SFM at the tip of a ball end mill so depending on material and rough or finish cut you may need to make adjustments to what you would otherwise do.

End mills are commonly used in milling machines, which are machines that use rotary cutters to remove material from a workpiece. The milling machine moves the workpiece against the rotating end mill, which cuts into the material and removes chips of material to create a desired shape.

Bull cutters are great for surfacing, especially in the up/down direction.  I've used 3" indexable cutters to surface a slope on a three axis setup, and I was able to get good finish with a pretty large stepover.  You're never cutting with the center and it acts like a noticeably larger ball.  The zero SFM at the center is why five axis programmers will tilt the tool when possible so as to never cut with the center; sometimes you can do it with four axis or even three axis setups too, if you have options on how to orient your part.

eMastercam - your online source for all things Mastercam. Together, we are the strongest Mastercam community on the web with over 56,000 members, and our online store offers a wide selection of training materials for all applications and skill levels.

It is important to choose the right end mill for your project to achieve the desired outcome. Understanding the different types of end mills and their intended uses can help you make the right choice. It is also important to consider factors such as the material being milled, the depth of cut, and the feed rate when selecting an end mill.

Using end mills can be a rewarding experience for beginners with the right tips and techniques. Secure the workpiece, choose the right speed and feed rate, use the right cutting depth, clear chips often, lubricate the end mill, and test the cut before milling the entire workpiece. By following these tips and techniques, beginners can use end mills effectively and achieve high-quality results.

If you are new to machining, you might be wondering what an end mill is. An end mill is a type of cutting tool that is used in milling applications. It is a rotating tool that is used to remove material from a workpiece. End mills are usually made of high-speed steel (HSS) or carbide and come in a variety of shapes and sizes. They are available in solid and indexable milling styles

Together, we are the strongest Mastercam community on the web with over 56,000 members, and our online store offers a wide selection of training materials for all applications and skill levels.

Image

For those who like to run mostly waterlines and horizontals, a 3 or 4 flute works just fine depending on the shape of your geometry.

On 3-d surfacing there is alot of downward ramping motion so a 2 flute has the best chip clearance.....yes I use only 2-fl for 3-d surfacing...

. Please enter the desired qty for the material(s) you want to include in your promotion or Proceed Without Promotion and only your base materials will be added to the cart.

Register now to participate in the forums, access the download area, buy Mastercam training materials, post processors and more. This message will be removed once you have signed in.

Your friend needs a different end mill vendor.  If you look at a 3-flute ball there is one flute that goes past center.  A 4-flute ball has two relieved and two meeting at center like a two flute.  That being said if you MUST spend a lot of cut time using the tip, as murlin said you will probably have more success with a two flute.

The end mill is named after its cutting end or tip, which is shaped like a cylinder or ball at the end of a long shank. They feature several end types for cutting, flutes, and point angles.

Understanding the Different Types of End Mills is an essential part of learning how to mill. End mills come in a variety of shapes and sizes, each designed to perform a specific type of milling operation. Here are some of the most common types of end mills and their uses:

Yes I like to give anyway from a 5 to 30 deg kick when surfacing using a ball endmill. You would no problem doing 5 Axis Programming.

Mitsubishi have a 3 flute ball nose tools with all 3 flutes to center (some of the other Japanese manufacturers do too IIRC).

End mills are versatile tools that can be used to cut a variety of materials, including metal, plastic, wood, and composites. They are used in a variety of industries, including manufacturing, aerospace, and automotive.

Choosing the right end mill for your project is crucial to achieving the desired outcome. Here are some factors to consider when selecting an end mill:

http://www.harveytool.com/prod/Browse-Our-Products/Application-Specific-Designs/Diamond-Tooling_190/PCD-Diamond-End-Mills---Ball_99.aspx

Using end mills can be a challenging task for beginners, but with the right tips and techniques, it can be a rewarding experience. Here are some tips and techniques to help beginners use end mills effectively:

I like to do a lot of scallop machining and most of the parts I do are complex with a lot of features so scallop does a lot of ramping down.

Yes I like to give anyway from a 5 to 30 deg kick when surfacing using a ball endmill. You would no problem doing 5 Axis Programming.

Image

Ive never done any 5 axis(dream of mine...sigh...) but I've heard that if you must use a ball nose and have 5 axis you should tilt the cutter as to not use the tip.

Image