Photo by Clint PattersonChoosing the right milling tool can be difficult. With all of the different brands, types, and sizes to choose from, it is easy to feel overwhelmed and not know where to start.
This post has compiled a list of factors that will help you narrow down your choices when selecting milling tools for your business.
Tool Coatings
Tool coatings are one of the most important aspects to consider when buying a milling tool. Coatings such as an end mill ball can increase or decrease tool life depending on which type you use, and they help keep your devices sharp for more extended periods without needing as much maintenance.
In addition, tool coatings make it easier to control heat generation, improve chip removal rates, reduce breakage on the tool, and offer other benefits. Tool Coatings can be applied to a milling cutter by any of three methods: plasma-arc deposition (PAD), flame spraying (FS), or chemical vapor deposition (CVD).
For PAD coating, the hot gas from an electric arc is directed at the cutting edge of the rotating tool to form a thin layer on the surface. In FS, molten metal is sprayed against a rotating device and then quenched by air or water. Finally, in CVD, vaporized elements are deposited onto the outer surfaces of heated tools while they rotate through an arc-shaped electric field.
Flute Count
Flute count is important for several reasons and can be one of the most challenging features to understand. The flutes on drills, end mills or other milling tools are the spiral grooves that help break chips free from the material getting cut.
They also increase surface contact between device and part, which helps remove debris more quickly during milling. The number of flutes on a given milling tool gets measured in the number of grooves per inch or GPI.
The higher the GPI for an endmill, drill bit, or other cutting tools, the more aggressive it will be when machining and removing material faster than desired if not used with caution. Milling tools with a higher GPI are typically used for heavy cutting, aggressive machining, or more challenging materials.
The lower the number of grooves per inch on these types of milling tools, the less aggressive they will be. They may require slower speeds to remove material efficiently without overheating the tool or workpiece.
Tool Life
Tool life is the duration of time before a tool needs resharpening. Therefore, the longer you can mill without needing your tools sharpened, the higher quality and less expensive your products will be.
For example, most high-quality steel lasts for about 1000 hours on average when machining aluminum metals. However, the steel used in softer materials like plastics may only last 100 hours.
The best way to know for sure is to talk with a knowledgeable salesperson at your local machine shop or machinery dealer if you have one nearby. If not, check out some online forums and ask other machinists what they are using on their machines. Hope this list helps you choose the right milling tool for your next home project.
