Was ist ein Schaftfräser??

1. Definition and Key Features of End Mills
1.1 What is an End Mill?
An end mill is a multi-flute rotary cutter with cutting edges on both its end face and sides, allowing simultaneous axial and radial cutting. This enables it to perform not only drilling operations like drill bits but also complex machining of planes, cavities, slopes, and curved surfaces.

1.2 Kernvorteile

• 3D Cutting Capability: Performs both radial and axial cutting for complex contours
• High Material Removal: 3-5× more efficient than drill bits (2-8 Flöten)
• Precision Machining: Optimized helix angle (30°-45°) reduces cutting resistance (Ra0.4μm achievable)
• Wide Applicability: Diameter range from 0.1mm (micro-machining) to 50mm (heavy-duty)

2. Key Differences Between End Mills and Drill Bits
2.1 Cutting Method

• Schaftfräser: Radial + axial cutting (slots/contours/3D surfaces)
• Bohrer: Only axial feed (hole drilling)

2.2 Flute Design

• Schaftfräser: 2-8 helical flutes for chip evacuation
• Bohrer: Typically 2 straight flutes (10°-20° helix)

2.3 Accuracy

• Schaftfräser: ±0.005mm repeatability
• Bohrer: ±0.02mm accuracy

2.4 Applications

• Schaftfräser: Mold cavities, impeller blades, precision slots
• Bohrer: Bolt holes, locating holes

3. Main Types and Applications
3.1 Flat End Mill

• Features: 90° square end
• Am besten für: Face milling, square shoulders
• Avoid: Curved surfaces

3.2 Ball Nose End Mill

• Features: Spherical tip
• Am besten für: 3D contour finishing
• Avoid: Schruppen

3.3 Corner Radius End Mill

• Features: R0.2-2mm edge radius
• Am besten für: Stress reduction in corners
• Avoid: Sharp internal corners

3.4 Roughing End Mill

• Features: Serrated teeth
• Am besten für: Heavy stock removal (5×D depth)
• Avoid: Abschluss

3.5 Aluminum End Mill

• Features: High flute volume + polished edges
• Am besten für: Non-ferrous metals
• Avoid: Gehärtete Stähle (>45HRC)

4. Selection Guidelines

4.1 Materialabstimmung

4.2 Machining Phase Optimization

• Schruppen: High feed (0.2-0.4mm/z), deep cuts (3-5×D)

• Abschluss: Low feed (0.05-0.1mm/z), shallow cuts (0.1-0.3×D)

4.3 Maschinenkompatibilität

• High-speed CNC: Small carbide tools (Ø3-10mm)

• Conventional mills: HSS tools (Ø10-25mm)

5 Tips to Extend Tool Life

1. Pre-cut Inspection: Check for edge defects (<0.02mm Rundlauffehler)

2. Coolant Strategy:

   • Aluminium: MQL

   • Rostfrei: 8-12% emulsion

   • Titan: >70bar oil

3. Proper Regrinding: Maintain original helix angle (±0.5°)

4. Chip Monitoring: Watch for discoloration/chip shape changes

5. Storage: 20±2°C with VCI paper

6. Future Trends

• Miniaturization: <Ø0.1mm for medical devices
• Smart Tools: IoT-enabled wear sensors
• Advanced Coatings: Nano-composite coatings

Abschluss
End mills are indispensable for precision machining. Key takeaways:
✅ Match tool geometry to material
✅ Optimize parameters for each machining phase
✅ Implement proper maintenance routines
✅ Stay updated on smart manufacturing trends

By mastering these principles, you’ll maximize machining efficiency and tool longevity.