CHANGZHOU CHINA MACHINERY TECHNOLOGY CO,LTD.

Post Industrial Revolution the innovations in mechanical processing technology never stopped. Since millennia, from manual operation, to numerically controlled machine tools, the innovation of tools has long been the core driving force for the progress of the industry. The end mill is one kind of cutting tools, it has high efficiency, high precision and high adaptability, and has become one of the indispensable "processing weapon" in modern manufacturing. The End Mill is essential whether you need it for precision components in the aerospace field or complex molds in the automotive manufacturing. The contents of this article will focus on "what are end mills used for" and analyze the appointment value of the End Mill in various fields.

The End Mill: Definition and Main Functions

The End Mill is used as multi tooth rotary cutting tool. Its cutting edges are arranged on the end face and the side surface of the tool, and it can do multi-direction cutting to the workpiece through rotary motion. Unlike common turning tools, the End Mill can both process plane and complete the cutting task of complex geometric figures, such as slot, and curved surface, step, etc. It's fit for devices like milling machine and machining center (CNC).

Its core functions include:

Material removal: Remove unwanted excess materials quickly out of metals, plastics etc.

Multi-axis Connection: Realizing the machining of complex contours.

Surface optimization: Enhance the surface quality and dimensional precision of the part.

Main Types and Applications of the End Mill

General-purpose End Mill

The most common type of end mill is the standard end mill. The insert cutting edges are distributed on the end face and the side edges, applicable to planar milling, side wall machining and shallow slot cutting. Take design process of mold manufacturing for example, this kind of tool is commonly used to machine the reference surface and the cavity structure of mold plate.

Ball Nose End Mill

Ball Nose End Mills also has a hemispherical end, which is suitable for machining three-dimensional curved surfaces and complex contours, such as the streamlined internal cavity of the automotive engine cylinder block and the curved surface of the aerospace parts impeller. The arc-shaped cutting edge reduces the cutting vibration and improves the surface quality.

Slot End Mill

Slot End Mill has been specifically developed for slotting. The width of the cutting edge is equal to the width of the slot, which is suitable for processing precision grooves such as keyways, T-shaped grooves, etc. For instance, in the processing of mechanical transmission components, Slot End Mill can efficiently finish the cutting of gear groove.

Multi-edge End Mill

The multi-edge design (such as 4 edges, 6 edges) can improve the cutting efficiency and is suitable for rough machining and semi-finishing in mass production. For example, it is used to machine the aluminum alloy mobile phone casings or the frames of electronic devices.

The Core Application Fields of the End Mill

Automotive Manufacturing

An End Mill is used for precision milling of engine cylinder blocks and transmission gears in the machining of automotive parts. Such as the Ball Nose End Mill can machining the crankshaft complex curved surface, and the Slot End Mill is used for the channel forming of the brake disc.

Aerospace

The requirements for lightweight and high strength of aerospace parts are extremely high. Due to the use of high-rigidity materials (carbide) and precision coating technology, the End Mill can use machining of difficult-to-cut materials (titanium alloys, high-temperature alloys, etc.) and structural parts of aircraft wing ribs.

Mold Manufacturing

The cavity of the mold, the parting surface and other complex structures need to rely on the Ball Nose End Mill, precision multi-edge tools can complete. How to obtain a high surface finish characteristics for machining the injection mold runner, which has the characteristics of high speed rotation and small cutting depth.

Electronic Devices

As for consumer electronic, the End Mill could be used to machine the precision holes and card slots of the same aluminum alloy or plastic casings, e.g. CNC milling of the middle frame of a smartphone.

Selection and Optimization of the Usage of the End Mill

Material Selection

Carbide: Fair for high speed cutting and high hardness material (stainless steel etc).

Cermet: In finishing, it can improve the surface quality and extend the tool life.

Geometric Parameters

Helix angle: A large helix angle (eg. 45°) is suitable for light cutting of aluminum alloy, and a small helix angle (eg. 30°) is suitable for heavy cutting of steel parts.

Coating technology: Coatings like Titanium Aluminium Nitride (TiAlN) can decrease friction and increase the high-temperature resistance.

Process Optimization

Adaption of cutting parameters: the rotational speed, feed rate and cutting depth depending on hardness of material.

Application of coolant: Using the coolant reasonably, can reduce the tool wear, and improve the surface accuracy.

Emerging Trends and Technologies

Whether it is intelligent manufacturing or green manufacturing, the advancement of the two will push the End Mill in the direction of high precision, long life and environmental protection. Such as the new cermet End Mill, design new optimized coating and flute structure, achieving the carbon steel, stainless steel "one tool for dual use, reduce the tool change time, improve efficiency. Moreover, if the intelligent tool monitoring system is employed, it can offer real-time feedback about the tool wear state, which leads to a decreasing of the processing cost.

Conclusion

Known as the "versatile tool" of mechanical processing, End Mill has application scenarios that cover almost all manufacturing fields. From the development of general-purpose types to special-purpose types, from rough machining to finishing, the End Mill has continued technological iteration, and continues to meet the industry's demand for efficient, accurate and reliable processing. In the upcoming generation, the overall performance of the End Mill will be able to be further improved based on the integration of materials science and numerical control technology, which will massively help the intelligent upgrading of the manufacturing industry and provide solid technical support.