Milling Cutters & Holders MACH 118: Lathe & Mill I Milling Cutters & Holders 9/2/2009 Compiled by: Ronald C. Schwartz

OBJECTIVES Identify common cutters for the vertical mill. After completing this unit, you should be able to… Identify common cutters for the vertical mill. Select a proper cutter for a given machining task. 9/2/2009 Compiled by: Ronald C. Schwartz

CUTTING TOOLS & HOLDERS FOR VMM tab End Mills The most frequently used cutting tool for the vertical milling machine is the end mill. End mills may have two, three, four, or more flutes and may be right- or left-hand cutting. 9/2/2009 Compiled by: Ronald C. Schwartz

CUTTING TOOLS & HOLDERS FOR VMM tab End Mills To determine the cutting direction of an end mill, observe the cutter from its cutting end. Fig. J-8 End mill nomenclature (Regal Cutting Tools). 9/2/2009 Compiled by: Ronald C. Schwartz

End Mills Two-flute end mills can be used for plunge cutting. tab CUTTING TOOLS & HOLDERS FOR VMM tab End Mills Types of end teeth on end mills. Two-flute end mills can be used for plunge cutting. Called center cutting because they can make their own starting hole . 9/2/2009 Compiled by: Ronald C. Schwartz

End Mills tab Four-flute end mills are also used for center cutting. CUTTING TOOLS & HOLDERS FOR VMM tab End Mills Types of end teeth on end mills. Four-flute end mills are also used for center cutting. If center drilled or gashed on the end, cannot start their own holes. Used in end milling if the cut is begun off the workpiece or in a premachined hole or cavity. A four-flute end mill is stronger than two- or three-flute end mills, permitting maximum feed rates. 9/2/2009 Compiled by: Ronald C. Schwartz

CUTTING TOOLS & HOLDERS FOR VMM tab End Mills A corner radius or chamfer on an end mill increases cutter life by preventing corner chipping. These cutters are also called “bull-nose” end mills. End mill with corner radius. 9/2/2009 Compiled by: Ronald C. Schwartz

High-Speed Steel (HSS) Helical & Straight Fluted End Mills CUTTING TOOLS & HOLDERS FOR VMM tab High-Speed Steel (HSS) Helical & Straight Fluted End Mills The high-speed steel end mill is a commonly used cutter for the vertical mill & may: Single-end helical tooth end mill.) Be single ended… Two-flute double-end helical-tooth end mill. double ended… Straight-tooth single-end end mill. or have straight flutes. (Weldon Tool - A Dauphin Precision Tool Brand) 9/2/2009 Compiled by: Ronald C. Schwartz

HSS Helical Fluted End Mills CUTTING TOOLS & HOLDERS FOR VMM tab HSS Helical Fluted End Mills High/fast helix angles are available, with selection depending on the machining task. Aluminum is machined efficiently with a high-helix- angle cutter & a highly polished cutting face to minimize chip adherence. Forty-five-degree helix angle aluminum cutting end mill. 9/2/2009 Compiled by: Ronald C. Schwartz

Roughing and Tapered End Mills CUTTING TOOLS & HOLDERS FOR VMM tab Roughing and Tapered End Mills A roughing end mill is used when large amounts of material must be quickly removed (roughed) from the work- piece. Also called hogging end mills Multiple teeth are in contact with the work, reducing the possibility of vibration or chatter. Roughing mill (Illinois Tool Works, Inc.). 9/2/2009 Compiled by: Ronald C. Schwartz

CUTTING TOOLS & HOLDERS FOR VMM tab Tapered End Mills Tapered end mills are used in mold making, die work & pattern making. Tapered end mills have included tapers ranging from 1 degree to more than 10 degrees. Also called diesinking mills. Fig. J-16 Three-flute tapered end mill. 9/2/2009 Compiled by: Ronald C. Schwartz

CUTTING TOOLS & HOLDERS FOR VMM tab Ball End Mills Ball-end end mills have two or more flutes and form an inside radius or fillet between surfaces. Used in mold making and in die-making operations. Two-flute single-end ball-end and mill. (Weldon Tool). 9/2/2009 Compiled by: Ronald C. Schwartz

Corner-rounding & Dovetail Cutters CUTTING TOOLS & HOLDERS FOR VMM tab Corner-rounding & Dovetail Cutters Precise convex radii can be machined with corner- rounding end mills. Corner-rounding milling cutter. Dovetail Cutter. Dovetails are machined with single-angle milling cutters. Two commonly available angles are 45 degrees and 60 degrees. 9/2/2009 Compiled by: Ronald C. Schwartz

Woodruff Milling Cutters CUTTING TOOLS & HOLDERS FOR VMM tab Woodruff Milling Cutters Woodruff keyseats are cut into shafts to retain a Woodruff key. Woodruff keyseat cutters come in many different standardized sizes. Woodruff keyslot milling cutter. (Illinois Tool Works, Inc.) Woodruff Key 9/2/2009 Compiled by: Ronald C. Schwartz

T-slot Milling Cutters CUTTING TOOLS & HOLDERS FOR VMM tab T-slot Milling Cutters T-slots in machine tables and work-holding devices are machined with T-slot cutters. T-slot cutters are made in sizes to fit standard T-nuts. T-slot milling cutter. 9/2/2009 Compiled by: Ronald C. Schwartz

Flycutters CUTTING TOOLS & HOLDERS FOR VMM tab A flycutter is a single-point tool often consisting of a high-speed or carbide tool in an appropriate holder Often used for light face cuts from large surface areas. Flycutter with an HSS tool installed 9/2/2009 Compiled by: Ronald C. Schwartz

Shell Mills Used for face milling operations. CUTTING TOOLS & HOLDERS FOR VMM tab Shell Mills Used for face milling operations. 9/2/2009 Compiled by: Ronald C. Schwartz

Cutter Holding on the Vertical Mill CUTTING TOOLS & HOLDERS FOR VMM tab Cutter Holding on the Vertical Mill Collet holders are widely used to securely mount milling cutters in the machine spindle.. The most rigid type of these is the solid collet or solid tool holder. Solid collet. 9/2/2009 Compiled by: Ronald C. Schwartz

Cutter Holding on the Vertical Mill CUTTING TOOLS & HOLDERS FOR VMM tab Cutter Holding on the Vertical Mill The split collet is widely used to hold cutters on the vertical mill. Split collet. When pulled into a spindle taper by a drawbar, a split in the collet squeeze tightly against the end mill shank. It is possible for a cutter to be pulled from the collet because of heavy feed rates or a dull cutting tool. Helical flute end mills may also be pulled from the collet. A solid collet has setscrews to prevent cutter slippage. 9/2/2009 Compiled by: Ronald C. Schwartz

REVIEW What is the most frequently used cutting tool in the vertical milling machine? What type of end mill can be used for plunge cutting? Which type of end mill is stronger? Two or four flute. An end mill with a corner radius or chamfer is called a _____ Describe a double-end end mill. Helical fluted end mills are best at cutting what type of material? How/why does a roughing cutter allow for deeper cutting? 9/2/2009 Compiled by: Ronald C. Schwartz

REVIEW What type of cutting is performed by a shell mill? What are some advantages to using shell mills? What are the two main types of tool holders used in the vertical milling machine? 9/2/2009 Compiled by: Ronald C. Schwartz

QUESTIONS? 9/2/2009 Compiled by: Ronald C. Schwartz