What Does a Milling Cutter Do?

As the “industrial teeth” of modern manufacturing, milling cutters enable high-efficiency material removal through high-speed, multi-edge cutting. Compared to single-point tools, their alternating cutting mechanism delivers three key advantages:

1. Enhanced Heat Dissipation: Rotating teeth provide 30% longer cooling time per edge, extending tool life by 40%
2. Improved Stability: Multiple edges reduce vibration, achieving surface finishes up to Ra 0.4 μm
3. Unmatched Productivity: Enables higher material removal rates (например., face milling at 20 cm³/min)

Example: Aerospace turbine blade machining with ø16 mm 4-flute ball nose cutters (R0.8 mm) achieves:

• Feed per tooth: 0.08 миллиметр
• Cutting speed: 80 m/min
• 4 mm axial depth of cut
• Surface roughness: Ra 0.4 μm

Фреза Types and Applications
1. End Mills
Structure: Cylindrical body with peripheral/end cutting edges
Приложений:

• Precision mold cavities (например., smartphone components)
• 3D contouring (requires 5-axis CNC)
• Thin-wall aluminum machining

2. Face Mills
Key Specs:

• Диаметр: 80-315 миллиметр
• Зубы: Coarse (4-6), Medium (8-10), Fine (12-14)
  Case Study:
• Блоки двигателя: 300 min tool life with negative inserts

3. Slot Drills
Проектировать:

• Body width = slot size (например., 10 mm tool for 10 mm slot)
• Chip gullet depth: 60% диаметра
  Industrial Use:
• Hydraulic valve T-slots (±0.05 mm tolerance)

4. Form Cutters
Technical Requirements:

• Profile accuracy ≤0.02 mm
• High-precision holders (≤0.01 mm runout)
  Application:
• Turbine blade root slots

5 Key Selection Factors
Совместимость материалов

• Cast Iron: YG8 carbide (120 m/min cutting speed)
• Нержавеющая сталь: TiAlN-coated tools
• Композиты: Diamond-coated cutters

Precision Needs

• Черновая обработка: Coarse pitch (20 cm³/min MRR)
• Отделка: Fine pitch (0.05 mm radial engagement)

Совместимость с машинами

• CNC: Check max shank diameter (например., BT40 holder)
• Spindle-to-table clearance: ≥300 mm

Industry Case Studies
Jet Engine Blades:

• Tool: ø16 mm ball nose cutter
• Results: 40% faster cycle, Ra 0.4 μm finish

EV Battery Housings:

• Strategy: Trochoidal milling → 120 cm³/min MRR
• ROI: 35% cost reduction

Why This Matters
This guide provides actionable insights for selecting and using milling cutters. Implement these strategies to boost machining efficiency and gain competitive advantage.