A dovetail endmill (sometimes referred to as a fishtail end mill) is specifically designed to cut dovetail grooves and slots. They work on many materials, but are most commonly employed in wood. The tip of the tool is angled to match the desired dovetail angle — typically 45 degrees — but they’re available with other tip angles as well.

Ismail, S., et al.: Recent advances in twist drill design for composites machining: a critical review. Proc. Inst. Mech. Eng.-Part B-J. Eng. Manuf. 231(14), 2527–2542 (2016)

Konneh, M., et al.: Surface roughness study of milled carbon fiber Reinforced polymer (CFRP) composite using 4 mm 2-flute titanium aluminum nitride (TiAlN) coated carbide end Mills. Adv. Mater. Res. 887, 1101–1106 (2014)

Milling machines come in various configurations and sizes. However, they share several key features and components essential for their operation such as:

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Koboević, N., Jurjević, M., Koboević, Ž.: Influence of cutting parameters on thrust force, drilling torque and delamination during drilling of carbon fibre reinforced composites. Tehnički Vjesnik 19(2), 391–398 (2012)

Carbon fiber reinforced polymerPDF

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Haddad, M., et al.: Study of trimming damages of CFRP structures in function of the machining processes and their impact on the mechanical behavior. Compos. B Eng. 57, 136–143 (2014)

Gaitonde, V.N., et al.: Analysis of parametric influence on delamination in high-speed drilling of carbon fiber reinforced plastic composites. J. Mater. Process. Technol. 203(1–3), 431–438 (2008)

Yashiro, T., Ogawa, T., Sasahara, H.: Temperature measurement of cutting tool and machined surface layer in milling of CFRP. Int. J. Mach. Tools Manuf. 70, 63–69 (2013)

Li, H., et al.: Machining quality and cutting force signal analysis in UD-CFRP milling under different fiber orientation. Int. J. Adv. Manuf. Technol. 98(9–12), 2377–2387 (2018)

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Soft materials are typically machined using standard HSS (high speed steel) devices such as square, ball, or flat end mills. Hard materials require carbide, diamond-like carbon (DLC), or aluminum titanium nitride (AlTiN) coated HSS for improved wear resistance. Abrasive materials like composites demand end mills with wear-resistant coatings. Heat-resistant materials require end mills with specialized coatings to reduce friction and heat generation. Sticky-cutting materials (e.g., some plastics and aluminum alloys) may require end mills with high helix or variable flute designs in order to evacuate chips. Brittle materials such as ceramics require specialized end mills designed for low-speed machining to minimize the risk of cracking. Composite materials may demand end mills with diamond or polycrystalline diamond (PCD) tips to prevent delamination. Wood cutting often uses standard end mills, while plastics may benefit from sharp or single-flute end mills to reduce melting and burning.

Senthilkumar, M., Prabukarthi, A., Krishnaraj, V.: Study on tool wear and chip formation during drilling carbon fiber reinforced polymer (CFRP)/titanium alloy (Ti6Al4V) stacks. Procedia Eng. 64, 582–592 (2013)

Milling machines generally have a coolant system that delivers cutting fluid or coolant onto the cutting tool and workpiece. It acts to dissipate heat, improve tool life, and enhance surface finishes. Machines often also include features for chip management — such as chip conveyors or chip augers — to remove chips and swarf generated during machining and leave the cutting space clear and unobstructed. Enclosures with electrical cut-off interlocks protect operators from flying debris and create a safer working environment. In CNC machining centers, a tool changer is used to automatically swap pre-calibrated and racked tools that have been prepared for later machining stages. Various gripping devices such as vises and clamps serve to secure the workpiece on the worktable. These can be customized, quick-release, or more generalized devices.Â

Durão, L.M.P., et al.: Drilling tool geometry evaluation for reinforced composite laminates. Compos. Struct. 92(7), 1545–1550 (2010)

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Sundi, S., et al.: Influence of router tool Geometry on surface finish in edge trimming of multi-directional CFRP material. IOP Conf. Ser.: Mater. Sci. Eng. 469(1), 012026 (2019)

Wang, Y.G., et al.: Cutting performance of carbon fiber reinforced plastics using PCD tool. Adv. Mater. Res. 215, 14–18 (2011)

Wang, X.M., Zhang, L.C.: An experimental investigation into the orthogonal cutting of unidirectional fibre reinforced plastics. Int. J. Mach. Tools Manuf. 43(10), 1015–1022 (2003)

Kim, K.S., et al.: Machinability of carbon-fiber epoxy composite-materials in turning. J. Mater. Process. Technol. 32(3), 553–570 (1992)

Haiyan, W., et al.: Analysis of cutting forces in helical milling of carbon fiber–reinforced plastics. Proc. Inst. Mech. Eng., Part B: J. Eng. Manuf. 227(1), 62–74 (2012)

Additionally, end milling can improve the surface finish of workpieces when employed as a post-process following casting or other less refined cutting techniques. It is precise and accurate, making it suitable for tasks that demand tight tolerances. End milling is a key process in both prototyping and production environments, allowing you to scale production from trial to moderate and potentially high-volume production.

The purpose of end milling is to precisely cut and shape materials to create specific features, profiles, and surfaces. It efficiently removes material from workpieces, cutting portions away until the item’s shape meets the planned dimensions. End milling also allows for the creation of complex shapes, contours, and intricate geometries in workpieces. Beyond that, it can create simple slots, pockets, and holes of various sizes and depths in workpieces.

Aerospace manufacturers use end milling to produce critical components like aircraft structural parts, engine components, and turbine blades. Its automotive use is widespread for engine blocks, cylinder heads, transmission components, tooling, and other parts. The tool and die industry relies heavily on end milling when creating molds, dies, and tooling of all types. End milling is used on printed circuit boards (PCBs) and electronic enclosures and components. The medical industry employs end milling to manufacture surgical instruments, orthopedic implants, dental prosthetics, and medical devices. End milling is used for creating intricate designs in wooden furniture and toys. It can also shape and cut plastic and composite materials. End milling is used in the production of components for energy generation and distribution, including wind turbine parts, gas and steam turbine components, and power transmission equipment.

Qin, X.D., et al.: Delamination analysis of the helical milling of carbon fiber-reinforced plastics by using the artificial neural network model. J. Mech. Sci. Technol. 28(2), 713–719 (2014)

Zemann, R., Kain, L., Bleicher, F.: Vibration assisted machining of carbon fibre reinforced polymers. In: 24th DAAAM International Symposium on Intelligent Manufacturing and Automation, vol. 69, pp. 536–543 (2014)

A ball end mill is a cutting tool with a hemispherical tip. It is designed to provide precision contouring, slotting, and machining of complex 3D shapes. The spherical tip allows for smooth and accurate machining of concave surfaces, filets, and curved profiles, smoothing the cuts into each other with minimal aliasing. Ball end mills can be used for both roughing and finishing operations — as well as in 3D contouring applications — simply by varying cut depth and feed rate. They generate lower cutting forces than do flat end mills, as the cut transitions into the material progressively along the bit’s radius. Ball end mills come in single-flute, two-flute, and multi-flute designs to suit different machining needs. The variations each clear chips differently.Â

Nurhaniza, M., et al.: Analyzing the effect of machining parameters setting to the surface roughness during end milling of CFRP-Aluminium composite laminates. Int. J. Manuf. Eng. 2016, 1–9 (2016)

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Brinksmeier, E., Janssen, R.: Drilling of multi-layer composite materials consisting of carbon fiber reinforced plastics (CFRP), titanium and aluminum alloys. CIRP Ann. Manuf. Technol. 51(1), 87–90 (2002)

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The spindle is a rotating drive that holds the cutting tool, generally in a collet chuck. It provides the rotational power necessary for material removal. The worktable is where the workpiece is clamped or mounted. It can move in multiple directions — X, Y, and Z axes in the most basic setup and up to 12 degrees of freedom in more advanced machines. Guideways are linear bearings or rails that guide the movement of the worktable and other machine components. They ensure smooth and precise motion even while the cutter is applying forces. In a CNC machine, the control panel houses the machine's control system and programming features, which allows the operator to input G-code and machining parameters and monitor the machining process. Manual machines use hand controls and generally have a 3-axis position measurement system. The tool holder or chuck securely holds the end mill on the spindle.

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Shyha, I.S., et al.: Drill geometry and operating effects when cutting small diameter holes in CFRP. Int. J. Mach. Tools Manuf 49(12–13), 1008–1014 (2009)

A V-bit or V-carving mill is a specialized cutting tool that’s meant for engraving and carving operations. The conical tip with a sharp point allows for precise engraving and detailing. V-bits excel in engraving text, logos, decorative patterns, and fine details on all materials. They come in various angles, but the most popular are 60° and 90°.

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Carbon fiber reinforced polymer material propertiesand uses

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Lee, C.K.: Structure, electrochemical and wear-corrosion properties of electroless nickel-phosphorus deposition on CFRP composites. Mater. Chem. Phys. 114(1), 125–133 (2009)

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Islam, F., Ramkumar, J., Milani, A.S.: A simplified damage prediction framework for milling of unidirectional carbon fiber-reinforced plastics. Adv. Manuf.-Polym. Compos. Sci. 1(4), 175–184 (2015)

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Won, M.S., Dharan, C.K.H.: Chisel edge and pilot hole effects in drilling composite laminates. J. Manuf. Sci. Eng. 124(2), 242–247 (2002)

A corner rounding end mill is a specialized cutting tool used to round the sharp internal corners of a workpiece. It features a cylindrical shank with a radiused tip. Various radius sizes are offered, allowing machinists to select the curvature they want for internal corners. They are used for creating tool-defined filets on internal (and to a lesser extent external) corners of cuts. Rounding sharp corners removes sources of stress concentrations in parts. These tools are ideal for contouring and finishing work.

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Klotz, S., Zanger, F., Schulze, V.: Influence of clamping systems during milling of carbon fiber reinforced composites. Procedia CIRP 24, 38–43 (2014)

Davim, J.P., Reis, P.: Study of delamination in drilling carbon fiber reinforced plastics (CFRP) using design experiments. Compos. Struct. 59(4), 481–487 (2003)

Çelik, Y.H., Kilickap, E., Kilickap, A.I.: An experimental study on milling of natural fiber (jute)-reinforced polymer composites. J. Compos. Mater. 53(22), 3127–3137 (2019)

Nor Khairusshima, M.K., et al.: Tool wear and surface roughness on milling carbon fiber-reinforced plastic using chilled air. J. Asian Sci. Res. 2(11), 593 (2011)

Santiuste, C., et al.: Modelling thermal effects in machining of carbon fiber reinforced polymer composites. J. Reinf. Plast. Compos. 33(8), 758–766 (2014)

Traditional milling, often referred to as conventional milling, differs from end milling primarily in the direction of tool rotation and the cutting forces applied during the machining process. End mill tools rotate in the same direction as the feed motion, which is typically clockwise when viewed from above. This means that the cutting edges on the bottom and side of the end mill engage with the workpiece simultaneously.

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Krishnamoorthy, A., Boopathy, S.R., Palanikumar, K.: Delamination prediction in drilling of CFRP composites using artificial neural network. J. Eng. Sci. Technol. 6(2), 191–203 (2011)

Carbon fiber reinforced polymer material propertiesand applications

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Isbilir, O., Ghassemieh, E.: Delamination and wear in drilling of carbon-fiber reinforced plastic composites using multilayer TiAlN/TiN PVD-coated tungsten carbide tools. J. Reinf. Plast. Compos. 31(10), 717–727 (2012)

Technology-oriented applications are becoming more important in today’s world and the use of technological processes continues to grow rapidly, day by day. Because of the advantages offered by composite materials, there is a great deal of interest in this material group in various industrial applications. Composite materials continue to develop at a great pace in parallel with the developments in metallic, ceramic and polymeric materials. Therefore, composite materials have found wide usage in engineering materials in recent years. In this material group, carbon fiber reinforced polymer (CFRP) composite materials, from the advanced composite material class, are commonly preferred in strategic applications due to their outstanding features such as high load-carrying capacity and low density. In this study, the production, characteristics and industrial usages of CFRP composite materials, milling and drilling operations carried out on them are presented along with current technology-oriented applications.

Roughing end mills are employed in first-stage roughing operations to quickly remove material before finishing cuts are made with finer tools. This tool class enables high material removal rates.

The content appearing on this webpage is for informational purposes only. Xometry makes no representation or warranty of any kind, be it expressed or implied, as to the accuracy, completeness, or validity of the information. Any performance parameters, geometric tolerances, specific design features, quality and types of materials, or processes should not be inferred to represent what will be delivered by third-party suppliers or manufacturers through Xometry’s network. Buyers seeking quotes for parts are responsible for defining the specific requirements for those parts. Please refer to our terms and conditions for more information.

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Carbon fiber reinforced polymer material propertieswikipedia

It's essential to consult with machining shops or service providers to determine the specific cost of end milling for a particular project. Luckily, at Xometry, our instant quoting engine makes getting pricing and lead times for machining projects simple.

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Carbon fiber reinforced Polymercost

Morkavuk, S., et al.: Cryogenic machining of carbon fiber reinforced plastic (CFRP) composites and the effects of cryogenic treatment on tensile properties: a comparative study. Compos. Part B-Eng. 147, 1–11 (2018)

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In conventional milling, the cutting tool rotates in the opposite direction to the feed motion (typically counterclockwise when viewed from above). This results in cutting forces that can push the workpiece down onto the worktable. End milling tends to produce smaller, more manageable chips, which can help it clear chips and extend the tooling’s lifespan. Conventional milling tends to produce larger, continuous chips, which can be more challenging to evacuate.

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A finishing end mill is a specialized cutting tool used to achieve high-precision surface finishes and tight tolerances on workpieces. Finishing end mills often have high helix angles, which help evacuate chips, increase the angle of attack for finer cutting, deliver better surface qualities, and reduce heat buildup during cutting. They are used to make fine cuts to minimize cutting forces and vibrations.

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End milling is commonly used for profile cutting, slotting, contouring, and complex 3D machining tasks. Conventional milling is more often used for facing, squaring, and smoothing out flat surfaces.

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Square end mills feature flat, square-shaped tips with sharp corners. The flat, square tip allows for straightforward machining of flat surfaces, slots, and profiles with sharp corners. Square end mills are suitable for both roughing and finishing operations on all materials. They are excellent for creating sharp 90° corners and edges. Square end mills are best suited to general-purpose cutting. They exist as two-flute, four-flute, and multi-flute types for different machining requirements.

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A roughing end mill can efficiently remove significant amounts of material from a workpiece, especially during the initial stages of machining. It is designed with a coarse and rugged geometry that allows for aggressive material removal while withstanding high cutting forces. Key features of a roughing end mill include multiple flutes, coarse tooth design, high helix angles, corner radii, and Weldon shanks.

Carbon fiber reinforced polymer material propertiespdf

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End milling is ideal for machining workpieces with complex shapes, contours, and intricate profiles because it can cut in multiple directions at once. It’s also great at creating slots or narrow channels in a workpiece. End milling allows for customization and precision when profiles with specific shapes or features need to be cut. Milled items come away with good finishes on flat, even surfaces. With careful tool selection, this technique is suitable for all cuttable materials. End milling ensures accuracy and repeatability when you need tight tolerances and high precision. It is also used in both prototyping and production scenarios, making it easy to scale up for mass production.

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Carbon fiber Reinforced polymerprice per kg

End milling is a machining process used in metalworking, woodworking, and other material shaping/removal processes. It is used to cut or shape materials using a rotating end mill. The process is used for a wide range of tasks, including: slotting, contouring, facing, and profiling workpieces. End milling can be used to create a huge range of features on a workpiece such as slots, pockets, holes, complex contours, and mixed forms. It is a fundamental process in manufacturing and is employed across all manufacturing sectors to precisely cut and shape: metals, plastics, wood, stone, and composites. The choice of end mill type, size, and cutting parameters depends on the specific machining requirements and the material being worked on.

End milling is used to remove material from the surface of a workpiece. It begins with the workpiece securely clamped onto the machine's work table or fixture. The spinning end mill is brought into contact with the workpiece's surface, and the cutting edges engage the material. The machine's spindle rotates at high speed to minimize vibration and cut cleanly. The work table itself moves the workpiece around the fixed cutting spindle. As the end mill rotates and the workpiece advances, the cutting edges of the end mill remove material from the workpiece's surface. Chips that get cut away are continuously removed from the cutting zone by the machine's chip evacuation system or by the motion of the end mill itself. The machinist or CNC (computer numerical control) program controls the speed, feed rate, depth of cut, and toolpath.

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Chair of Engineering Mechanics, Faculty of Mechanical Engineering, Institute of Mechanics, Otto von Guericke University Magdeburg, Magdeburg, Sachsen-Anhalt, Germany

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Before beginning any milling operation, you must first select the right end mill tool for your material. The material’s hardness, abrasiveness, thermal conductivity, and chip properties are all important considerations.

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The cost of end milling varies significantly, depending on the number of parts required, the material type, precision, surface finish, custom workholding, and task geometry/complexity.

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