When shopping for a roughing end mill, it is important to consider certain key factors. This includes flute length, helix angle, and cutting speeds. By understanding these basics of a quality roughing end mill, you can ensure you are getting the right tool for the job.
Optimal cutting speeds.
When shopping for a roughing end mill, it’s important to consider the optimal cutting speeds. A general rule is that slower feeds and speeds should be used when roughing in order to maintain good tool life and chip control. If speeds become too fast, you may run into problems with increased wear on your end mill as well as potential issues with burring or chipping. Knowing the right speeds for the material and depth of the cut will ensure a smoother, safer cut.
Maximum flute length.
One feature to assess on your roughing end mill is the maximum flute length, as this will directly impact how efficient your mill is at removing material. Generally speaking, longer flutes reduce chip load and also provide more efficient cuts. Longer flutes are particularly ideal for materials that have a tendency to chip or break when shorter tool lengths are used. When choosing a roughing end mill, make sure you select one with an appropriate flute length for the task at hand.
Right helix angle.
The helix angle on a roughing end mill also plays an important role in efficiency. Countersinking offers excellent chip clearance and maximum metal removal rate, but will cause large torque swings that can put additional stress on your machinery. The right helix angle for your application depends on a variety of factors, so be sure to consult with the manufacturer to ensure you get the best results.
Chip evacuation capability.
A high-speed roughing end mill should offer maximum chip evacuation capability. You should look for flutes that have the appropriate length and a large enough exit angle to allow chips to escape without clogging or jamming the cutting edges. Chip clearance is especially important when machining thicker materials, as long chips can cause chattering, vibration, and poor cutting performance. Additionally, cooler running tools are better able to provide consistent performance throughout longer runs.
Effective cutting parameters control.
Maximum chip evacuation performance should be combined with machining parameters that are comfortable for operators and the machine. Helix angles should be chosen in order to target specific materials, and cutting speeds chosen to achieve maximum performance without producing heat damage or producing too many chips. By precisely controlling the conditions of each cut an operator can ensure long-lasting tool life and high-performance results.
