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End Mill Basics
END MILLS: have cutting edges on both the end and sides, permitting end cutting and peripheral cutting. Center cutting types permit plunge and traverse milling.
CUTTING EDGE: Select sharp edged for faster speeds. Select radial edged for longer tool life.
SHANK DIAMETER: Select largest diameter available to maximize rigidity and minimize axial deflection and chatter.
NUMBER OF FLUTES: Select fewer flutes for milling softer materials at higher feeds and speeds where more chip space is required or when machine horsepower is limited.
Select more flutes for milling tougher materials at reduced feeds and speeds or for increased table feeds using the same cutting speeds.
TOOL DIAMETER: Select largest practical diameter to maximize
rigidity, minimize chatter and improve tool life. If machine spindle speed is limited, the largest practical diameter permits higher cutting speeds.
COATINGS: are especially effective (see “Coating Selector”). Stocked coated end mills are available with TiN, TICN, and TIAIN in many sizes.
FLUTE AXIAL RELATIONSHIP:
Select straight flutes for a wide variety of applications.
Select right spiral flutes for improved cutting action and easier chip removal.
Select left spiral flutes for use in absorbing impact shock when entering steel workpiece – maintains constant hold down pressure and minimizes chatter. Useful in profiling applications where recutting chips causes premature cutter dulling.
Select high spiral (15º or more) to dramatically improve cutting action, finish, chip removal, and tool life. High spirals distribute impact load more evenly throughout the tool’s entire revolution.
End Mill Specifications & Tolerances
- Geometry, carbide grade, O.D. relief and end clearance appropriate for material being machined
- Flute long carbide tips brazed to tough hardened alloy steel body
- Spiral flute carbide tips formed to true helix angles
- Straight shanks have standard Weldon drive flats
- Non-center cutting end mills have the ends cleared to depth of carbide
- Precision ground cutting edges
- USCTI
- Tool diameter tolerance:
- Radial edged: plus .002″, minus .000″
- Sharp edged: plus .005″, minus .000″
- Shank diameter tolerance:
- minus .0001″, minus .0005″
End Mill Problem Solving Guide – Carbide Tipped
| AVOID PROBLEMS BY CAREFUL ORIGINAL SET-UP | ||
| MACHINE CONDITION | Tool holder in good condition and secure part holding fixture | |
| TOOL CONDITION | Use cutting tool recommended for material being machined. Avoid excessive tool overhang. | |
| FEEDS & SPEEDS | Start with feeds and speeds recommended for material being machined | |
| COOLANT | Coolant flow must be adequate to avoid intermittent quenching and to flush chips promptly, avoiding the recutting of hardened chips. | |
| MILLING PROBLEMS | POSSIBLE CAUSES | POSSIBLE SOLUTIONS | |
| 1. | ROUGH FINISH | Dull cutting edge | Resharpen to original tool geometry |
| Wrong feeds & speeds | Increase speed – also try reduced feed | ||
| 2. | EXCESSIVE CUTTING EDGE WEAR | Wrong feeds & speeds | Increase feed (should always be over .001″ per tooth) – especially when machining ductile or free machining materials. Also try reduced speed |
| Rough cutting edge | Lightly hone cutting edge with fine grit diamond hone | ||
| Insufficient coolant | Increase coolant flow – review type of coolant | ||
| 3. | CHIPPED CUTTING EDGE | Poor chip removal | Use tool with larger flute space – larger diameter or fewer flutes |
| Recutting work hardened chips | Increase coolant flow | ||
| Vibration | Increase rigidity of set-up, especially worn tool holders | ||
| Incorrect carbide grade | Change to tougher carbide grade | ||
| 4. | CHATTER MARKS | Insufficient machine horsepower | Use tool with fewer flutes as correct feeds & speeds must be maintained |
| Vibration | Consider climb milling Use larger diameter cutter Resharpen tool with more clearance | ||
| 5. | GLAZED FINISH | Feed too light | Increase feed |
| Dull cutting edge | Resharpen tool to original geometry | ||
| Insufficient clearance | Resharpen tool with more clearance | ||
| 6. | POOR TOOL LIFE | Excessive cratering | Increase speed or decrease feed Change to harder grade of carbide |
| Milling abrasive material | Decrease speed and increase feed Increase coolant flow Climb milling better than conventional milling | ||
| Milling surface scale | Conventional milling better than climb milling | ||
| Milling hard materials | Reduce speed – rigidity very important | ||
| Insufficient chip room | Use larger diameter tool | ||
| Delayed resharpening | Prompt resharpening to original geometry will increase tool life | ||
| Thermal cracked carbide | Maintain adequate coolant flow at all times Climb milling is cooler than conventional milling | ||
End Mills Index and Comparison Chart
| DESCRIPTION | HANNIBAL | CLEVELAND | FULLERTON | GREEN- FIELD/ RTW | MORSE | NYTD | NIAGARA | UNION | |
| PAGE | TYPE | ||||||||
| CENTER CUTTING END MILLS | |||||||||
| Straight Flutes- For Non-Ferrous & Cast Irons | 134, 136 | 314 | 60SK | SKM | 5935 | 4800 | 5689 | ||
| Straight Flutes- For Steels | 138, 140 | 312 | 60SKS | 5936 | 4780 | 5688 | |||
| 25° Right Spiral Flutes- For Non-Ferrous | 132, 135 | 318 | 60CS | 5966 | |||||
| HIGH SPIRAL SHEAR CUTTING END MILLS | |||||||||
| 15° Right Spiral Flutes- For Non-Ferrous & Cast Irons | 133, 137 | 375 | HLS | 5692 | 4737 | 4840 | 5002 | ||
| 15° Right Spiral Flutes- For Cast Irons & High Temp Alloys | 137, 143 | 320 | |||||||
| 15° Right Spiral Flutes- For Steels | 139, 141 | 350 | 60GSS | HES | 5960 | 4733 | 4820 | 5001 | |
| 25° Right Spiral Flutes- For Non-Ferrous (Sharp Edged) | 133 | 327 | |||||||
| 25° Right Spiral Flutes- For Non-Ferrous | 133, 135 | 325 | 60FS | HNS | 5958 | 4731 | 4860 | 5003 | |
| SLOW SPIRAL END MILLS | |||||||||
| 6° Right Spiral Flutes- For Non-Ferrous (Sharp Edged) | 132 | 307 | |||||||
| 6° Right Spiral Flutes- For Non-Ferrous & Cast Irons | 132, 136 | 306 | 766 | 60RS | RSEM | 5921 | 4700 | 5682 | |
| 6° Right Spiral Flutes- For Steels | 138, 140 | 308 | 60RSS | 4736 | |||||
| 6° Left Spiral Flutes For Steels | 140, 142 | 310 | 767 | 60LSS | LSEM | 5964 | 4738 | ||
| STRAIGHT FLUTES END MILLS | |||||||||
| Sharp Edged- For Non-Ferrous (4 Flutes) | 132 | 305 | |||||||
| Radial Edged- For Non-Ferrous & Cast Irons (2 Flutes) | 134, 136 | 302 | 765 | 60TF | TFEM | 5923 | 4732 | 4700 | 5680 |
| Radial Edged- For Non-Ferrous & Cast Irons (4 or 6 Flts.) | 134, 136 | 304 | 765 | 60EM | EM | 5925 | 4734 | 4750 | 5680 |
| Radial Edged- For Steels | 138, 140 | 300 | 60TFS | 5927 | |||||
Coolant Fed End Mills General Information
Another Proven
Technology Expanded
- HANNIBAL IS EXPERIENCED – For many years we have manufactured carbide tipped coolant fed end mills on a special order basis. These coolant fed tools provide improved finishes & tool life, as the coolant reduces cutting temperatures and flushes chips away from the cutting edges.
- HANNIBAL IS COMMITTED to further developing its world class quality, service and value in carbide tipped cutting tools.
Improved Performance with Coolant Fed End Mills
- Center fed design flushes the chips away from the cutting edges, improving tool life and workpiece finish in cavities and deep slotting applications.
- Flute fed design applies the coolant to the radial cutting edges, improving tool life and workpiece finish in contouring and slotting operations.
- Available with BOTH modifications for the ultimate in coolant fed enhancements
Coolant Outlets Also Available on T-Slot Cutters
Side Milling
Slot Milling
T-Slot Milling