End Milling 101: Get to Know End Milling Basics

CNC machining is a versatile process, and end milling is also one of the techniques. If you are inclined to learn about the end milling process, essential factors to keep in mind during the process, and how it differs from drilling, this End Milling 101 has it all.

So, let's read.

What is End Milling?

CNC end milling has cutting tools that are used in milling machines.

These tools help remove material from the workpiece and are commonly opted to make different shapes in the workpiece or carve holes. The process of end milling is used in applications like contouring, profiling, and milling.

The end mill tools have a teeth-like edge which helps cut the workpiece in different directions. The process of end milling is suitable for use over various materials and their grades.

How the End Milling Process Works

The process of end milling helps cut the workpiece to achieve the desired shape. It has a rotating tool which is called an end mill.

The tool creates precise features and shapes by moving in the programmed direction and cutting the workpiece. The tools can move in vertical or horizontal and even angled paths.

The process of end milling is mostly opted to create pockets, slots, and contours which are complex. It is a versatile process that can handle a diverse range of materials.

Different Types of End Mill

There are different types of end mills and each of these offers different components with unique characteristics. Some of these types of end mills are discussed below:

Square End Mills

Square end mills are a very common kind that have a cutting edge in square form. It is usually opted for milling surfaces which require pockets and slots and are flat in shape.

Ball End Mills

Ball end mills have a round tip which helps in ensuring surface finishes to be smooth. It is commonly used for 3D modeling, contour milling, and shallow slotting.

Torus End Mills

Torus end mills also have a circular cutting edge, it is mostly used in making cuts where a specific size of radius is needed.

Roughing End Mills

Roughing end mills consist of multiple cutting teeth and also have a coarse pitch which helps remove material quickly. It is suitable for heavier machining operations.

Tapered End Mills

Tapered end mills have cutting edges that taper at the end. It is used in the application of die and mold where precision is critical.

Drill End Mills

The drill end mill is a multifunction tool that performs multiple operations of milling, drilling, chamfering, and countersinking.

Factors to Consider When Choosing an End Mill

When selecting end mills for manufacturing components of different applications, some of the factors that you must consider are given below:

• Every material requires different types of end mill tools. The harder materials require tools made using carbide whereas the softer ones may need high-speed steel for neat and precise cuts.
• If you cut the components that are coated, such coatings help to reduce friction while milling, and move the cutting performance.
• To ensure efficiency in cutting so that you get the right finish, and chip removal is efficiently achieved, you must consider the length, flute count, and helix angle.
• The tool of the end milling machine must match the speed and rigidity of the machine so that it performs optimally.

Advantages and Disadvantages of End Milling

The process of end milling comes with a combination of pros and cons and some of these are given below.

Advantages:

• End milling is a versatile process, it helps produce multiple shapes, which are composed of 3D shapes, pockets, slots, and even contours.
• The components manufactured using end milling have tight tolerance and they are highly accurate and suitable for detailed parts.
• End milling ensures that components manufactured offer a very smooth surface finish and hence the need for additional finishing reduces.
• There are multiple metals, plastics, and even composites that can be chosen for the end milling process.

Disadvantages:

• End mills can wear out very quickly when hard materials are cut using them or they are used at high speed.
• When you opt for a good quality end mill, you will find them expensive hence they need a high initial investment.
• If the process of milling is not controlled appropriately, it can lead to a lack of inaccuracy in dimensions and poor surface.
• The length and rigidity of the tool are limited due to which the depth of the cuts is also limited.

Differences Between End Milling vs Drilling

End milling and drilling are machining processes but they both have different purposes. The purpose of end milling is to create shapes that are complex and have pockets or slots.

The tool of end milling can also move in different directions and hence cuts at different angles, vertically, and horizontally. Also, the tool ends with multiple cutting edges.

However, the process of drilling is meant to create holes in components, it moves in an axial or linear direction and has two edges for cutting at the tip.

The end mill allows removing material from the side as well as the face of the tool and creates a precise shape. Whereas, the drilling cuts in one single downward direction and creates holes.

DEK: Your Partner for Various Milling Projects

If you also have an upcoming project where you need CNC-milled components of diverse materials, you can get in touch with DEK.

We have experience in offering custom-milled components that are suitable for your applications and provide you with high-quality parts that are precise and durable.

Conclusion: End Milling 101

The guide above features detailed information on the end milling process and going through it, you must have understood everything well.

Hence, this information is going to be very helpful in being hands-on in end-milling components for your projects and you will be able to make informed decisions regarding the process for manufacturing parts.

FAQs

Can you drill with an end mill?

Yes, we can drill with an end mill. However, it is not a recommended practice when you need deep holes.

What are the main differences between end milling and face milling?

Face mills allow making cuts perpendicular to the spindle axis of the tool, whereas end mills have their cutting edges on both sides as well as the ends of the cutting tool.