CHANGZHOU CHINA MACHINERY TECHNOLOGY CO,LTD.

Since the Industrial Revolution, metal processing technology has experienced a leap from manual operation to numerical control. In this process, the design of cutting tools has been continuously optimized to meet the processing requirements of higher efficiency and more complex shapes. As an indispensable member in modern CNC machining, the 4-flute end mill has become a "versatile" tool widely used in the manufacturing industry due to its unique structural advantages. This article will deeply explore its core uses and analyze why it occupies an important position in processing scenarios such as metals and composite materials.

Basic Structure and Design Principles of the 4-flute End Mill

Balance between the Number of Cutting Edges and Cutting Efficiency

The core of the 4-flute end mill is based on the symmetrical distribution of the four cutting edges. The four-flute features more cutting edges involved in cutting per unit time, so it can increase the feed rate and the material removal rate compared to two-flute or three-flute cutters. Meanwhile, it uses the distribution of the four cutting edges so that the cutting force can be dispersed to lower the tool vibration, to lengthen the tool service life.

Helix Angle and Chip Removal Efficiency

The helix angle of the majority of 4-flute carbide end mills is 30º to 45º. A higher helix angle allows for less resistance to chip removal. Especially in the sticky metals like aluminum or stainless, it can prevent tool abrasion and the work surface from scratching caused by chip accumulation.

Advantages of Carbide Material

The 4-flute end mill made of high-quality carbide material has greater hardness and heat resistance; it can be used for high-speed processing. It is 3-5 times higher than the life of high-speed steel tools, and suitable for processing of high hardness materials, such as quenched steel, titanium alloy.

Core Application Scenarios and Processing Advantages

High-Efficiency Finish Machining of Metal Materials

Processing of Aluminum Alloys and Non-Ferrous Metals

The 4-flute end mill performs particularly well in machining aluminum. Four flutes can handle higher spindle speeds (typically over 10,000 R.P.M.). It has a large helix angle for fast chip removal, can reach mirror-level machined surface, and is extensively applied to the precision machining of 3C product cases, automobile parts, and others.

Medium-load Cutting of Stainless Steel and Alloy Steel

Taking account of the feature of work hardening of stainless steel, the 4 flute carbide end mill with carbide substrate and coating technology (including TiAlN) can effectively reduce the cutting heat, avoid the surface burn on the material, and keep the dimensional accuracy.

Burr-free Cutting of Composite Materials

In the composite material of carbon fiber the glass fiber, each material has extremely high requirements for sharpness, and the chip removal property of the tip. The geometric angle of the cutting edge is optimized and the four-edged superfine end mill can effectively avoid delamination in high speed cutting and the edge is smooth with no burr, which is appropriate for manufacturing of aerospace structural parts.

Machining of Complex Profiles and Grooves

In case of mold making and machining complex parts, 4 flute end mills which have a multi-flute structure and have extra strong support, can perform multiple operations including side-wall machining, slope cutting, and roughing of shallow grooves by one time setting, reducing tool replacement frequency and increasing material removal rate.

Selection and Usage Precautions

Select the Edge Type and Coating According to Material Characteristics

General-purpose 4 flute end mill: Suitable for materials such as ordinary steel and aluminum. It is recommended to use uncoated or AlCrN-coated tools.

Special for high-hardness materials: Select an ultra-fine grain carbide substrate and match it with a TiSiN coating to enhance heat resistance.

Optimization Suggestions for Cutting Parameters

Feed rate: The feed per tooth (Fz) of the four-flute milling cutter is usually 0.05 to 0.15 mm and needs to be adjusted dynamically according to the hardness of the material.

Cooling method: When processing stainless steel or titanium alloy, it is recommended to use an internal cooling tool with high-pressure coolant to reduce the cutting temperature.

Avoid Common Usage Mistakes

Excessive pursuit of high speed: Although carbide tools are heat-resistant, too high a rotation speed may lead to coating peeling, and the recommended values provided by the manufacturer should be referred to.

Neglecting tool runout detection: When installing, it is necessary to ensure that the coaxiality error between the tool holder and the spindle is less than 0.005 mm; otherwise, edge chipping is likely to occur.

Maintenance and Cost-benefit Analysis

Regular Inspection and Edge Grinding

The carbide material of the 4-flute carbide end mill allows for multiple grindings (usually 3 to 5 times), and the cost of each grinding is only 30% of that of a new tool, significantly reducing the long-term usage cost.

Balance between Service Life and Processing Quality

By monitoring the fluctuation of cutting force or the change of surface roughness, the wear state of the tool can be predicted. Timely tool replacement can avoid workpiece scrapping and achieve dual control of quality and cost.

Conclusion: A Versatile Machining Tool for Multiple Scenarios

With its characteristics of high efficiency, stability, and versatility, the 4-flute end mill has become one of the core tools in modern precision machining. Whether it is high-efficiency finish machining of metal materials or defect-free cutting of composite materials, the four-flute end mill can significantly improve production efficiency and product quality through reasonable selection and parameter optimization. Understanding its design principles and application scenarios will help users maximize its value in different processing requirements.