Milling cutters are commonly used tools in machining, employed for cutting and shaping materials. Depending on the machining requirements and materials, the type and selection of milling cutters vary. This article will introduce several common types of milling cutters, the materials they are suitable for, differences between various milling cutters, and precautions during machining.

Types of Milling Cutters

1. Face Milling Cutter
   Face milling cutters are used for machining flat surfaces, suitable for materials like steel, cast iron, and aluminum. These cutters usually have multiple cutting edges, enabling efficient material removal.

2. End Mill
   End mills are used for slotting, stepping, and machining complex contours. They can work on various materials, including stainless steel, copper, and plastics. The characteristic of end mills is that the tool’s end can also cut, making it ideal for machining internal details.

3. Ball Nose End Mill
   The cutting edge of a ball nose end mill is spherical, commonly used for finishing three-dimensional surfaces. It is suitable for harder materials like alloy steel and stainless steel. Ball nose end mills are widely used in mold manufacturing and aerospace industries.

4. Slitting Saw
   Slitting saws resemble saw blades and are suitable for cutting and dividing materials. They are commonly used for machining thin-walled parts and are appropriate for materials like steel and aluminum.

Differences Between Various Milling Cutters

Milling cutters are mainly distinguished by their shape, material, and coating:

• Shape: As mentioned earlier, different shapes like face mills, end mills, ball nose mills, etc., lead to varied applications.
• Material: Milling cutters are usually made from High-Speed Steel (HSS) or Carbide. HSS tools are suitable for softer materials, while carbide tools are ideal for high-speed cutting of harder materials.
• Coating: Coatings like Titanium Nitride (TiN) and Titanium Carbonitride (TiCN) can enhance the wear resistance and lifespan of the cutters.

Machines Suitable for Milling Cutters

Milling cutters are commonly used in CNC milling machines, vertical milling machines, and horizontal milling machines. The type of milling machine determines the method of using the cutters and the machining results. For instance, CNC milling machines allow for precise machining and can achieve complex 3D surface processing, while traditional vertical or horizontal milling machines are suitable for conventional planar and slot machining.

Precautions During Machining

1. Cutting Speed and Feed Rate: Choose appropriate cutting speed and feed rate based on the material and type of milling cutter to avoid excessive tool wear or poor surface quality.

2. Coolant Usage: For high-temperature materials or high cutting speeds, the use of coolant is crucial. It can effectively reduce the cutting temperature and extend tool life.

3. Tool Wear Inspection: Regularly check the wear condition of the milling cutter and replace it if necessary to ensure machining accuracy and surface quality.

4. Safety Operation: During milling, always wear proper protective equipment, such as safety glasses and gloves, to prevent injuries from flying chips.

Machines Used for Manufacturing Milling Cutters

The production of milling cutters usually involves CNC grinding machines, which can precisely control the shape and dimensions of the tools. Additionally, laser processing and Electrical Discharge Machining (EDM) are also used in the manufacturing of milling cutters, particularly for complex shapes and high-hardness materials.