These feature radically altered bit shapes, allowing cutting to take place at up to 33,000 RPM. Manufacturers create these to improve the performance of machining tools capable of higher feed rates and revolutions per minute (RPM). High balance end mills are also available. Off-set chip breaker geometry reduces chip size for enhanced evacuation while leaving workpiece surfaces semi-finished. Standard two- and three-flute mills (discussed below), have serrated edges designed to scoop chips from cutting surfaces and run at higher rates for better feed performance. Chipbreaker tools, for instance, improve chip evacuation. Taper end mill for making grooves and holes, and for side-milling at an angle.īesides general shape, various tooling options are also available for end mill. Corner radius end mills are usually reserved for milling molds and dies, since getting flat-bottom pockets and rounded contours don’t require as many tool changes with these Ball nose end mills are for when you want to create rounded contours and flat-bottomed pockets Long neck end mills reduce interference between the workpiece and the tool and are usually for pocketing Square end mills, also known as flat end mills, are for plunge cutting, profiling, slotting, and side milling The shape you choose will typically depend on the nature of the machining you want to do, and not the material itself. The geometry of the end mill typically refers to its basic shape and design. It is just a cylindrical piece of metal from which manufacturers cut the flute. The shank is the part of the tool that does not have an edge. It runs from the tip of the bit all the way to the shank. The flute is the section of the bit that contains the cutting edge. Selecting Standard 1: Geometry End mills comprise a shank, neck, flute, and edge. Here’s everything you need to know about end mill standards for aluminum: Therefore, choosing end mill with the correct geometry, coatings, flutes, and angles, is essential. Because of this, a friction-induced fusion between the end mill and material can occur, destroying both the piece being milled and the equipment. Compared to steel, aluminum has a much lower melting point. The main challenge in machining aluminum milling is heating. Making incorrect choices could dramatically increase production costs and affect the quality of the finished product. However, if you are looking to mill thousands of items per week, then your choice of bit matters considerably. It is highly heat-resistant and offers superior machinability compared to cast.įollow our guide to find your right end mill for aluminum is so easy If you are looking to machine aluminum as a one-off, making the right end mill selection doesn’t matter a great deal. Wrought aluminum is a purer metal, making it less abrasive. It costs less to produce and contains significant quantities of other elements, including magnesium and silicone. Cast aluminum offers higher flexibility and lower tensile strength. Aluminum is suitable for advanced milling techniques of the kind found in most factories.Ģ Types of Industrial Aluminum There are two general types of industrial aluminum: cast and wrought. Not only is the metal abundant in the Earth’s crust, but it is also extremely light and flexible, making it ideal for numerous applications across industries.įurthermore, manufacturers love the metal because it is easy to machine. In this guide, we take a look at aluminum as a material, and then how to select a suitable end mill for drilling into it.Īluminum Material Profile Aluminum is one of the most machined materials on the planet. In most cases, you have a range of options that will fit the bill. The good news is that there isn’t usually one right answer unless you are doing very specialist work. And because of this, it can be hard to know which to choose for your application. Manufacturers make hundreds of different types of end mills for aluminum machining. Guide to Selecting an End Mill for Aluminum Machining
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