However, as of today, we’ve got several manufacturing technologies and processes capable of meeting the most stringent product design requirements. One of such manufacturing processes is called face milling.

CNC milling is a CNC process that involves the use of rotating cutters to remove portions of a block of material (or workpiece) till the desired custom shape (or feature) is made. It allows manufacturers to create intricate parts accurately while meeting tight...

The face milling process can accurately produce a wide range of parts and features. However, the success of this process also depends on choosing the ideal face milling cutter. Let’s take a look at three common cutters.

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With a certain slope, making the tool larger at one end and smaller at the other end, the model is expressed in a way that is different from the normal tool. For example, the slant cutter with the model number 10×3 means the diameter of the smaller end of the cutter is 10mm and the slant of the cutter is 3°.

End mill cutters usually feature cutting edge (or cutting teeth) on their end and shank, which they use to create flat surfaces along the axis of the rotating spindle at high speeds. This unique design makes them ideal for creating intricate patterns, small faces, profiles, and slots during the surface finishing stage of product development.

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Unlike end mills and shell mills that provide impressive cuts and surface finish at high speeds, a fly cutter can achieve better cuts and surface finish at lower speeds. That means a machinist will require less power to create high-quality cuts using the fly cutter.

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Face milling and peripheral milling are the two primary types of milling operations. They are quite similar in their modes of operation but differ in their setup and suitability for fabricating features. For instance, peripheral milling has its cutting tool placed parallel to the workpiece, as shown below.

Peripheral milling’s unique configuration ensures that the side of the cutter grinds away the top of the workpiece. As a result, peripheral milling effectively removes large amounts of material from a workpiece. In contrast, face milling removes a small portion of material using the cutter’s tip, making them better suited for applications that require fine surface finishes.

Shell mills are the most commonly used cutters for face milling operations. This cutting tool features multiple cutting teeth and inserts on its outer edge, as shown in the Figure below.

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④Milling larger planes such as mold fractal surface, in order to improve productivity and reduce the processing surface roughness value, the general use of insert insert disc milling cutter.

Semi-finishing process: round insert milling cutter (diameter range of 10-25mm round insert milling cutter), ball end mill.

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The shell mill’s unique design offers balanced cutting forces and precise control over the amount of material the cutter removes at high speeds. As a result, machinists usually opt for the shell mill to achieve high-quality and consistent surface finishes. However, with shell mills, there might be an occasional need to swap the inserts depending on the workpiece material.

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It is very important to optimize the cutting process by selecting a specialized combination of tool size, flute and grade, as well as cutting parameters and a suitable milling strategy.

①Flush milling cutters, also called flush gongs, short milling cutters, mainly used for milling small planes or step surfaces for roughing, finishing, profile finishing and card clearing (root clearing).

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③ Ball cutter (ball milling cutter), also known as ball gong cutter, R cutter, is mainly used for surface finishing (such as mold cavity and core processing), in order to ensure that the cutting edge of the tool and the processing contour in the cutting point tangent, and to avoid interference between the cutting edge and the contour of the workpiece, generally use ball milling cutter, rough machining with two edges milling cutter, semi-finishing and finishing with four edges milling cutter. The surface roughness is large and the efficiency is low when roughing and finishing the plane with ball end mills.

In general, mold CNC machining, the tool used is a more complex system, how to make the correct choice according to the actual situation, and set the correct parameters in the CAM software, is the CNC programmer must master. Only the basic knowledge of the tool, structure and selection of a full understanding and knowledge, and continue to accumulate experience, in the actual work can be used flexibly, so as to improve efficiency and production efficiency and ensure safe production.

Gensun Precision Machining offers rapid prototyping and precision machining services for innovative companies around the world. Whether you need a custom prototype, low-volume production, or high-volume production, our service is second to none. With a strong emphasis on quality control, we get the job done right, every time!

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Die milling cutters are used to machine mold cavities or convex mold forming surfaces. Die milling cutters are evolved from end mills and can be divided into three types according to the shape of the working part: conical flat head, cylindrical ball head and conical ball head. Carbide mold milling cutter is very versatile, in addition to milling a variety of mold cavities, but also can replace the hand file and grinding wheel grinding head to clean the cast, forging, welding workpiece burrs, as well as some forming surface finishing processing. The milling cutter can be mounted on the wind or power tools, productivity and durability than the grinding wheel and file to improve dozens of times!

The cutting speed is 50.9m/min. Feed of the main spindle (vf). Check the item you want to calculate, input values in the two ...

Gensun is a leading provider of machining services across Asia. Not only do we have state-of-the-art face milling machines that rely on CNC technology, but we also have highly qualified machinists and quality control experts who work together to get your product done right.

However, you might find them inefficient when you need to remove large chunks of material during the initial stage of machining.

The evolution of CNC machining has been marked by significant technological advancements. From the early days of punch tape and rudimentary programming, CNC machining has evolved to incorporate sophisticated software and high-speed, multi-axis machines. In recent...

The replaceable carbide insert on each tool is easily rotated to expose a sharp cutting edge by loosening the T15 Torx head screw with the included key and ...

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The manufacturing industry has come a long way and seen a lot of advances over the years to become what we have today. For instance, back in the 18th century, skilled workers fabricated parts using conventional hand tools. Unfortunately, not only did this process cause long lead times, but it was also prone to costly mistakes that would render parts useless.

Face milling is a type of CNC milling process―which means it involves removing portions of material from a workpiece using cutting tools. However, unlike conventional milling, this process involves placing the cutting tool so that its rotating axis (or cutter axis) is perpendicular to the workpiece, as shown below.

② rounded corner milling cutter, also known as round nose cutter, bull head cutter, cutter handle, mainly used for mold frame roughing, plane finishing, suitable for processing higher hardness materials. Commonly used round nose cutter corner radius is R=0.2~6mm. these cutters have good rigidity and good wear resistance, and are often used in rough machining occasions.

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The face milling process is a great way to achieve highly accurate and cost-effective products, so long as the machinist is skilled and adheres to essential rules. Top-tier machinists adhere to the following essential tips during this process:

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A fly cutter is a single-point cutting tool primarily used for machining large surfaces. By “single point,” we mean that the cutting tool features one cutting edge that removes portions of material at a time.

But what is face milling, and how does it work? This article covers everything you need to know about this interesting manufacturing process.

Companies around the world use CNC machining to craft high-quality components from diverse materials like ceramics, wood, and composites. Metal and plastic take the forefront in mass production, with metals enjoying wider machinability. Machinists can adeptly tackle...

Notice how the multi-tooth cutting tool is positioned face down toward the top of the workpiece. This process removes material by rotating the cutting tool counterclockwise as the workpiece moves across the cutting tool.