TYPES OF MILLING CUTTERS

Tom Beaumont

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18 years engineering experience, specializing in 3 & 4 axis CNC milling, turning and horizontal boring.

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An expert guide to the different types of milling cutters

Milling cutters are tools used in milling machines to perform various machining operations such as as slotting, shouldering, profiling, ramping, and plunging. Different types of milling cutters are designed to meet specific requirements based on the material being machined, the desired operation, and the shape or profile to be created.

This article will provide all the necessary information into the different types of milling cutter available, why and where you would use them and for what applications they are suitable for.

Different types of milling cutters

It's important to select the appropriate milling cutter based on the specific requirements of the machining task to achieve the desired results in terms of accuracy, surface finish, productivity, and tool life. The choice of cutter depends on factors such as the material being machined, the operation type, the desired profile, and the overall machining strategy.

Square end mill & slot drills

Both square end mills and slot drills are available in a range of sizes, materials and coatings to suit different workpiece materials, cutting conditions and machining requirements. The selection of the appropriate cutter depends on factors such as the desired slot dimensions, material hardness, machine speeds and the required surface finish.

Square/sharp corner end mills are versatile and can be used for roughing and finishing operations. Usually featuring 4 or more flutes end mills can create square-bottomed slots, pockets, and flat surfaces. However, due to its sharp corners, it may leave small marks or steps at the corners of the machined features.

Square/sharp corner slot drills are particularly useful when machining closed-end slots as they have the ability to plunge due to a centre cutting tooth. Usually featuring 1-3 flutes they are available in various widths and can create slots of different sizes. Slot drills are commonly used in milling machines to produce slots for keys, grooves, and other similar applications.

Ball Nose

A ball nose milling cutter is a type of milling tool with a spherical-shaped cutting edge. It is named "ball nose" because the cutting edge resembles the shape of a ball. The cutter has a rounded end portion that gradually transitions from the cutting edge to the shank of the tool.

Ball nose milling cutters are primarily used for creating contoured surfaces, 3D shapes and sculpted features on a workpiece. They are also used to create corner rads, some technical drawings will request corner rads as they are stronger than square corners. The ball-shaped cutting edge allows for smooth and consistent material removal, especially when machining curved or irregular surfaces. The spherical shape of the cutting edge enables the cutter to follow the contours of the workpiece, resulting in smooth transitions and improved surface finishes.

Corner Radius

A corner radius milling cutter is a type of milling tool that features a rounded cutting edge at the corner, forming a specific radius. Unlike a square end mill or a ball nose cutter, which have sharp corners or a spherical shape, respectively, a corner radius milling cutter has a radius at the corner where the cutting edges meet. Some people refer to these as bullnose cutters) also wort mentioning that the corner rad strengthens the cutting edge and stops it from chipping resulting in prolonged tool life.

Corner Rounding

A corner rounding milling cutter is a type of milling tool designed to create externally rounded corners on a workpiece. It has a cylindrical shape with a rounded cutting edge that gradually blends into the adjacent surfaces. This cutting edge is responsible for removing material and forming a smooth, rounded corner.

When selecting a corner rounding milling cutter, factors such as the desired radius size, workpiece material, cutting conditions, and machine capabilities should be considered to achieve the desired corner rounding results efficiently and accurately.

Chamfer Mill

A chamfer mill milling cutter, also known as a chamfer end mill or chamfer cutter, is a specialized type of milling tool designed to create chamfered edges or bevelled features on a workpiece. It is specifically designed to cut at a chamfer angle, forming a sloped edge or a bevelled surface.

Chamfer mill milling cutters are widely used in applications where chamfering or bevelling is required, such as in the preparation of edges for welding, improving part aesthetics, or creating chamfered features on machined components, using a chamfer mill can eliminate the need for manual deburring saving time and money. The choice of the chamfer mill cutter depends on factors such as the desired chamfer angle, material properties, cutting conditions, and machine capabilities.

Dovetail

A dovetail milling cutter is a specialised type of milling tool designed to create dovetail-shaped slots or grooves with precise angles. It is named after the dovetail joint, which is known for its interlocking wedge-like shape.

Dovetail milling cutters are essential tools for creating dovetail joints or mating surfaces that require precise interlocking profiles. The choice of the appropriate dovetail milling cutter depends on factors such as the desired dovetail angle, material properties, cutting conditions and the specific application requirements.

T-Slot/Woodruff

A T-slot milling cutter, also known as a Woodruff cutter, is a specialized type of milling tool used to create T-shaped slots or keyways in a workpiece. It is named after its inventor, William Woodruff, who developed the Woodruff key and the associated cutter.

T-Slot/Woodruff Geometry: T-slot milling cutters have a specific shape with a cylindrical body and a unique cutting edge profile. The cutting edge has a T-shaped groove that matches the dimensions of the desired T-slot or Woodruff keyway. The T-slot design allows for the insertion of T-nuts or other fasteners into the slot.

Rippers/Roughers

A ripper/roughing end mill, also known as a rougher, is a type of milling cutter specifically designed for removing large amounts of material quickly and efficiently. It is primarily used in roughing or preliminary machining operations, where the goal is to remove bulk material rather than achieve a fine finish.

Rippers/roughing end mills are particularly useful when machining large workpieces, removing excess material, or preparing a workpiece for finishing operations. They are capable of handling tough materials such as steels, cast iron, and other high-strength alloys.

When selecting a roughing end mill, factors such as material type, desired material removal rate, cutting conditions and machine capabilities should be considered to achieve efficient and effective roughing operations.

Reduced Neck/Long Neck/Rib Processing

A reduced neck milling cutter is a specialised type of milling tool that features a reduced neck diameter in relation to the cutting diameter. It is designed with a shorter flute length or a narrower shank diameter compared to standard milling cutters. This reduced neck design allows for improved tool stability, increased reach and enhanced performance in certain machining applications. Reduced necks offer clearance in shouldering and pocket milling application, it stops the shank rubbing when machining beyond the flute length

A long neck milling cutter or extended flute milling cutter, is a specialised type of milling tool designed with an extended neck or flute length compared to standard milling cutters. It features a longer neck that allows for deeper reach and access to hard-to-reach areas of a workpiece.

Rib cutter or rib processing end mill is a specialised type of milling tool designed for machining ribs or thin walls on a workpiece. It is specifically designed to create precise and consistent features, such as ribs or fins, with a high degree of accuracy and efficiency.

Taper Neck

Taper neck milling cutter, also known as a taper shank milling cutter or conical neck milling cutter, is a specialised type of milling tool that features a tapered shank or neck section. This design allows for increased tool rigidity, improved accessibility, and enhanced performance in specific milling operations.

Taper neck milling cutters are commonly used in various machining operations, including profiling, slotting, and contouring. They are suitable for machining materials such as metals, plastics and composites in industries such as aerospace, automotive, mold and die making and general machining. Taper necks are also referred to as a barrel cutter.

Side/Face Milling

A side and face milling cutter, is a type of milling cutter that is primarily used for machining flat surfaces, slots and profiles on the sides and faces of a workpiece. It is a versatile tool capable of performing multiple cutting operations in a single pass.

When using side and face milling cutters, it is important to consider factors such as cutting parameters, workpiece material, tool path strategy and machine capabilities to achieve desired machining results and tool holding. Proper tool selection and setup are essential for efficient and accurate milling operations with side and face milling cutters.

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