What Two Ways Are Milling Cutters types （Classified）?

The Complete Guide to Milling Cutter Classification: Structure vs. Application
紹介: Why Classification Matters
In mechanical machining, selecting milling cutter types directly impacts efficiency, cost, and quality. As core metal-cutting tools, milling cutters serve diverse needs through systematic classification. This guide analyzes the two fundamental approaches—by structure and application—to help you choose optimal tools for specific conditions.

I. Classification by Tool Structure
1. Solid Milling Cutters

• 特徴: Integrated body/teeth (HSS or Carbide)
• アプリケーション:

Small-batch precision (e.g., medical parts)

Aerospace thin-walled components

• Advantages:

High rigidity for 12,000 RPM cutting

40% fewer operational errors (no blade changes)

2. Indexable Milling Cutters

• 設計: Reusable body + replaceable inserts
• Economic Benefits:

Inserts cost 30% of tool price

50% faster insert replacement

• Use Cases:

Automotive mass production (e.g., engine blocks)

Wind turbine gearbox roughing

3. Brazed Milling Cutters

• Structure: Brazed carbide inserts
• Cost Advantage: 40% cheaper than solid types
• Limitation: Avoid high-heat environments
• Application: General steel rough machining

II. Classification by Cutting Function

1. Face Milling Cutters

• Function: Surface machining

• Optimization:

  • 30°-45° helix angles for chip control

  • Diameter = 1.2-1.5× workpiece width

• Scenarios:

  • Automotive engine block finishing

  • Gearbox base roughing

2. End Mills

• Versatility: Slots, cavities, 3D contours

• Tech Advances:

  • TiAlN nano-coatings 3× lifespan

  • Long-neck end mills (5:1 length ratio)

• 種類:

  • Ball-nose end mills (mold cavities)

  • Corn cob mills (heavy roughing)

3. Form Milling Cutters

• Custom Design: Gear/cam profiling

• Efficiency: IT7 tolerance in one pass

• アプリケーション:

  • Aerospace turbine blades

  • Transmission synchronizers

4. Angle Milling Cutters

• Angles: 45°-90° standards

• Specialized Use:

  • Double-angle cutters for titanium

  • V-grooves with dedicated adapters

• Tip: Use coolant for >60° angles

III. Selection Guide

Material-Based Choices

• >45 HRCの: Carbide-coated cutters (high red-hardness)
• Stainless Steel: PVD-coated brazed cutters (anti-adhesion)
• Aluminum: Fine-tooth HSS cutters (sharp edges)

Batch Production Tips

• High-volume (>500pcs): Indexable systems
• Small batches: Modular toolholders
• Prototypes: Solid cutters

Machine Compatibility

• CNC Centers: Indexable tools (auto-change compatible)

• Manual Mills: Solid cutters

• Material Strategies:

  • Aluminum: <3mm fine pitch

  • Titanium: >8mm coarse pitch

IV. Myth-Busting

• Myth 1: “Expensive = Better”
  ✓ Reality: Brazed cutters economize stainless roughing

• Myth 2: “Universal Tools Exist”
  ✓ Reality: Titanium needs anti-vibration grooves

• Myth 3: “Coolant Doesn’t Matter”
  ✓ Critical: Never use chlorine coolants with aluminum

V. Maintenance Tips

• Wear Limit: Replace at >0.3mm flank wear

• Storage: <60% humidity cabinets

• Optimization: +20% cutting speed = longer life

結論

The dual milling cutter classification system (structure/application) enables smarter tool selection. Key considerations:

1. Production scale (mass vs. single-piece)

2. Material properties (hardness, stickiness)

3. Equipment type (CNC/manual)

Pro Tip: Combine indexable systems for cost efficiency with solid cutters for precision. Optimal matching boosts productivity 20-35% and extends tool life 1.5×.