When an end mill has more flutes, it has more cutting edges, but that results in smaller channels for material to move along.  For that reason, you need to be aware of the “chip load,” which indicates the thickness of the material being removed by each of the cutting edges. The number of flutes should match the material being cut and the machine you are using.

Overall, end mills are versatile cutting tools used in a wide range of manufacturing and machining processes across various industries, including automotive, aerospace, electronics, mold making, and general machining. Their ability to create precise features and complex shapes makes them indispensable in modern machining operations.

RPM (revolutions per minute), or speed of the spindle, is often determined by the material being cut like mentioned above.

With such a variety of end mills available, you will be able to tackle any application. The experts at Skookum Tools are here to help find the right one for you, to ensure that all your projects go smoothly. Please take a look at our Skookum Brand End Mills HERE

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# of teeth, or the number of flutes on some cutters, is just that, the number of cutting edges on a tool. This will always be a whole number, often 1, 2, 3 or 4 for most endmills.

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End mills may be made from a variety of materials, such as high-speed steel (HSS), cobalt, or solid carbide, and feature finishes such as Titanium Nitride (TiN) and Aluminum Titanium Nitride (AlTiN) that will affect wear resistance, cutting ability, and the ability to run at higher speeds.

"Width of cut", some times referred to as side load or stepover, is how much the tool moves over for each pass. On most mills, this is usually controlled by how much the X and/or Y axis is moved.

Next, we need to determine our feed (cutting feedrate), or how fast we will be moving the cutting tool through the material. Typically, feedrate is noted in inches per minute (in/min) or millimeters per minute (mm/min). The formula and components needed to calculate feedrate are:

To have a better understanding of end mills and their uses, one needs to know what milling is. In basic terms, milling is a technique that uses a rotating cutting tool to carve out 3-dimensional shapes. As the end mill rotates, it removes material from the piece being worked, and its shape determines the result.

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To calculate your starting speeds and feeds, begin by finding the speed (RPM) recommended for the material you plan to cut. For this example we will use Aluminum, so the RPM we will be working with is 8,500.

Milling is done by inserting the chosen end mill into a milling tool holder that in turn is placed within the tool spindle on the machine.

Now that we have determined that the recommended starting speed and feed for cutting aluminum with a 2-flute endmill is 8500 RPM and 13.6 in/min., there are just two more values we need to figure out. These values, commonly known as "width of cut" and "depth of cut" are not always included when referencing speeds and feeds but they both have a large impact on whether the speed and feed you are using will work well or not.

Drilling: End mills with center-cutting capabilities can be used for drilling operations, allowing for both drilling and milling in a single operation. This is especially useful for creating holes with precise dimensions.

When needing to remove large amounts of material quickly and without vibration, roughing end mills are your choice. These are useful for speed but lack finesse. Roughing end mills have serrations that produce numerous small chips and rough edges (hence the name). There are roughing and finishing end mills, however, which not only remove heavy material, but also leave a smoother finish.

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Feed per tooth, sometimes known a chip load is the amount of material each tooth on the tool will cut every time it makes contact with the material as the tool turns. This is usually pretty small number.

In conclusion, if you wanted to cut aluminum with an 1/8", 2-flute endmill using a Pocket NC V2 machine, the recommended starting speeds and feeds would be:

Square end mills are used for most general applications, but as mentioned above, end mills come in a variety of shapes useful for achieving different effects. Centre-cutting end mills have cutting surfaces on both the sides and the face, which makes them the right choice for plunge-milling. Non-centre end mills only have cutting edges along their sides, and they are easily identified by a small hole in the centre and are used for side milling.

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Contouring and 3D Machining: End mills are essential for contouring and 3D machining applications, where intricate three-dimensional shapes and surfaces need to be produced with precision.

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As eluded to several times above, these values are simply a starting point and will likely need to be adjusted to optimize production or meet specific requirements.

•         Three flutes give a better finish to hard materials. Three flutes give the end mill greater strength but may cause issues with chip removal.

Facing: End mills can be used for facing operations, where the cutter removes material from the surface of a workpiece to create a flat and smooth finish. This is often done at the beginning of a milling operation to ensure proper alignment and surface preparation.

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"Depth of cut" is how deep the tool cuts on each pass. On most mills, this is usually in reference to the amount the Z axis moves before starting to cut laterally.

There is a lot to learn when it comes to speeds (spindle RPM) and feeds (cutting feedrate). To simplify things and give you a good place to start, we have created a really basic speeds and feeds chart for the Pocket NC V2. See the chart below* or download it from the bottom of the page and then continue reading to learn how to calculate your speeds and feeds. Note this chart was created with 1/8” single flute tooling in mind.

Profile Cutting: End mills are used to cut profiles or contours into a workpiece. They can create complex shapes, slots, pockets, and other intricate features with precision.

Slotting: End mills are commonly used to cut slots or grooves into a workpiece. They can create narrow or wide slots of varying depths and widths.

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In the chart above, the suggested starting depth of cut and side load (width of cut) are represented as percentages of the cutter diameter. So, if we were using an 1/8" diameter endmill to cut aluminum, we would calculate depth of cut and side load as follows:

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Ramping and Helical Interpolation: End mills are utilized for ramping and helical interpolation operations, which involve creating inclined or helical paths in the workpiece. This technique is commonly used in aerospace, automotive, and mold making industries.

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Ball end mills are another useful type of end mill and will produce a radius at the bottom of slots and pockets. They are put to good use when you need to do some contour milling, shallow slotting, or pocketing.

At first glance, you might think that end mills are just different types of drill bits. As the name suggests, however, end mills are used in milling applications and are a type of cutting tool.  There are several categories available, and they may be further divided by the application, such as slotting, side milling, tapering, or pocket milling.

*While these speeds will likely work on a V2-50, they are more suited for a V2-10. To achieve the best results on a V2-50, use the Harvey Tool chart above. You can also reference Proven Cut which has posted several recipes for aluminum, delrin and PEEK on the Pocket NC V2-50.

Flutes are the spiral-shaped cutting edges along the side of the end mill. During use, the material being cut away can move along these channels if the end mill is in a pocket or slot. Typically, there will be 2- 4 flutes.

Milling: End mills are primarily used for milling operations, which involve removing material from a workpiece to create a desired shape, profile, or feature. They can cut in various directions (up, down, or sideways) depending on the type of milling operation.

End mills are cutting tools used in milling operations, which involve the machining of a workpiece with a rotating cutter. These tools are commonly used in milling machines, CNC machines, and other machining equipment. End mills feature cutting edges on the bottom and sides and come in various shapes and sizes to perform specific tasks. Some common uses of end mills include: