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Rich Experience
Hangzhou Wagen Precision Tooling Co.,Ltd is a wholly-owned subsidiary of Ferrotec China Group, a Japanese diversified multinational group. It was established in 2000 with a total investment of 867 million yen.
Advanced Equipment
WAGEN has the most advanced technology and equipment from Europe, America and Japan, and has established a complete service system of R&D, manufacturing, sales and after-sales.
Reliable Product Quality
WAGEN adheres to the corporate philosophy of "diligence, determination, pioneering, and excellence" of Ferrotec China Group, keeps making progress and innovation, and establishes a sophisticated process flow, is committed to passing on the brand concept and high-quality products to every customer.
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Wagen Precision Products are widely used in producingspare parts of car and plane, Aluminum, Furniture, Wood and Plexiglas.
What is Milling Cutter?
Milling cutters are cutting tools typically used in milling machines or machining centres to perform milling operations (and occasionally in other machine tools). They remove material by their movement within the machine (e.g., a ball nose mill) or directly from the cutter's shape (e.g., a form tool such as a hobbing cutter).
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98mm Japan Diamond Milling Cutter
Inventory name: Diamond milling cutters. Specification and model: 98 * 10.5 * 15 * 4P. Usage:
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The main function of the pre-milling cutter is to milling the edge of the plate before the sealing
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This milling cutter is a diamond product，made using a five-axis machining center to process the
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Milling cutter： Pre-milling cutter is mostly used for trimming before edge banding machining of Jintian HOMAG equipment. Most of the silhouette knives are used for the silhouette processing of the floor factory, and the processing process is divided into rough machining, finishing, and finally completing the molding of the corresponding silhouette. V card knife is used in the electronic circuit board industry. The apex is V-shaped.
Advantages of Milling Cutter
Efficiency And Precision In Material Removal
One of the primary benefits of milling cutters is their ability to remove material efficiently and precisely. The multi-point cutting edges of these tools allow for continuous cutting action, leading to higher productivity. The precision of material removal is dependent on the type of cutter used, with some designed for roughing operations and others for finishing operations, thus enabling both rapid material removal and fine detailing.
Versatility And Flexibility In Machining Operations
Milling cutters offer versatility and flexibility in machining operations owing to their varied designs. For instance, end mills can perform multiple types of milling operations, including profiling, slotting, and contouring. Similarly, face mills are excellent for creating large, flat surfaces. This versatility allows a single machine to perform a wide array of tasks, contributing to operational efficiency.
Enhanced Surface Finishes And Tool Longevity
The design of milling cutters also contributes to enhanced surface finishes. For instance, radius end mills with rounded corners can produce a smoother finish compared to sharp-edged cutters. Furthermore, certain milling cutters, such as those with coated or carbide inserts, offer extended tool life, reducing the frequency of tool replacement and thus minimizing downtime.
Applications In Various Machining Processes
Milling cutters find applications in various machining processes, from basic shaping tasks to complex, high-precision operations. The choice of cutter depends on the specific process – thread milling cutters for creating threads, dovetail cutters for dovetail slots, and so on. This wide range of applications makes milling cutters an indispensable part of any machining setup.
High-Performance And General-Purpose Tooling
Milling cutters can be broadly classified into high-performance and general-purpose categories. High-performance milling cutters are designed to withstand high cutting speeds and feed rates, offering improved productivity and part quality. On the other hand, general-purpose milling cutters are designed for a wide range of materials and operations, offering flexibility in machining tasks. The availability of both types of tooling ensures that milling cutters can cater to a broad spectrum of machining requirements.
1. End Milling Cutter
It has teeth on either side, so it can be used very successfully in drilling operations. The term “end mill” is commonly used for flat bottom cutters. The basic difference between a drill bit and an end mill cutter is that the drill bit can only cut in the axial directions, but this Cutter can cut in all directions.
2. Roughing End Milling Cutter
Roughing mills are also known as “Pippa” cutters. These cutters give a great performance under the toughest operating conditions. As the names themselves suggest, it is used to extract large amounts of material. A wavy tooth is used from such cutters. These cutters make very small chips that result in a rough surface finish.
3. Periphery Milling Cutter
When the cuttings’ teeth are present on the circumference of the circular disc, it is known as a circumference mill cutter. Perimeter mill cutters can only be used for horizontal mill machines.
4. Side Milling Cutter
A side mill cutter is a type of Cutter in which the cutting teeth are present on the periphery and also on the face or end. This Cutter is mostly used in strand milling operations and face milling operations. It is also used to cut slots and mix deep and narrow slots.
5. Face Milling Cutter
Face mill cutters have a large diameter cutter body with several mechanically fastened insertion tools. A large amount of material is removed by making radially deep and axially narrow cuts. The diameter of the cutter body depends on the length of the workpiece and the available clearance on either side of the workpiece.
6. Gang Milling Cutter
It is the type of Cutter in which peripheral milling cutters of different sizes are cut together to remove material from the workpiece simultaneously.
7. Staggered Mill Cutter
Staggered mill cutters are staggered at the periphery with optional right and left-hand helix angles and are made to a relatively narrow width.
8. Concave Milling Cutter
A concave cutter is a type of formed Cutter. The form cutter is designed to have a specific shape on the workpiece. A concave milling cutter is a type of Cutter shaped to match a convex surface of a circular contour equal to half a circle or less.
9. Cylindrical Milling Cutter
A cylindrical mill cutter is a type of Cutter that has a cylindrical shape and has teeth only on the perimeter surface.
10. Hollow Milling Cutter
It resembles a pipe that has thick walls. The bites of hollow surfaces are on the inside surfaces. This Cutter is used in screw machines.
11. Woodruff Cutter
This tool is used to cut keyways for a wooden key. It is slightly hollow at the edges for relief, and the teeth are not side cuttings. Teeth come in both straight & staggered varieties.
Material of Milling Cutter
Carbon Tool Steel
This is an inexpensive metal material with good machinability for making mill-cutting tools. This material contains 0.6 -1.5% carbon and usually less than 0.5% of Manganese and silicon. It could also include metals like Chromium and Vanadium, depending on the grain size and hardness the manufacturer wants to achieve.
High-Speed Steel (HSS)
This is carbon steel but with a small amount of molybdenum, tungsten, chromium, and other alloying metals that makes it considerably different from conventional carbon steel. With the addition of these alloys, high-speed steel has a higher toughness, wear resistance, and hardenability, giving it a higher metal removal rate.
Cemented Carbide Tool and Cermet
This mill tool produced by the powder metallurgy technique is extremely hard and can withstand cutting operations at very high speed. This material, composed of tungsten, titanium carbide, and tantalum, remains hard up to 1000°C. There are different binders manufacturers use for binding the constituents of this tool, which include cobalt, nickel, and molybdenum.
Ceramic
This material is non-reactive and harder than its cermet counterparts. It also has better resistance to heat, wears, and tear resistance than Carbides. This heat resistance makes ceramic milling cutters ideal for milling super alloy workpieces. For hard materials, high heat is required for ceramics to function properly.
Stellite
This is a non-ferrous alloy material made only by grinding or casting. It contains different quantities of chromium and cobalt. It could also contain tungsten or molybdenum. Cutting edges using this material retain their quality even at extremely high temperatures and speeds.
Application of Milling Cutter
Milling Operations And Processes
Milling operations typically involve the use of multi-point cutting tools to remove material from a workpiece. Common operations include face milling (creating a flat surface or face on the workpiece), peripheral milling (cutting along the contour of the workpiece), and slot milling (creating slots or channels). The selection of milling cutters is highly dependent on the specific operation and the desired outcome.
Cutting Tools And Machine Operations
In machine operations, the cutting tool’s design significantly impacts the efficiency and quality of the machining process. Milling cutters, being rotary cutting tools, allow for continuous cutting action, which can increase the speed of machining operations. Different types of milling cutters, such as end mills for detailed cutting or face mills for broad surface cuts, cater to diverse machining requirements.
Material Removal And Surface Milling
Material removal is a fundamental aspect of machining processes. Milling cutters, with their multiple cutting edges, excel in removing material efficiently. They can be used for roughing (removing large amounts of material quickly) or finishing (creating a smooth surface). In surface milling, the cutter’s diameter, the number of cutting edges, and the feed rate all influence the quality of the surface finish.
CNC Milling And High-Performance Machining
In CNC (Computer Numerical Control) milling, milling cutters are controlled by a computer, enabling high precision and consistency. High-performance machining often involves the use of advanced milling cutters that can withstand high cutting speeds and feed rates, improving productivity and part quality.
Milling Process And Tool Applications
The application of milling cutters varies depending on the machining process. For instance, end mills are used for contouring and slotting, while face mills are used for creating flat surfaces. Selecting the right milling cutter for the application is crucial for achieving the desired part geometry and surface finish.
Helix Angle
Impact: The helix angle determines the angle at which the flutes wrap around the cutter. A higher helix angle helps in efficient chip evacuation and reduces the risk of chip recutting, which can lead to tool wear and poor surface finish.
Efficiency: A higher helix angle is generally more efficient in removing chips and reducing heat buildup.
Flute Count
Impact: The number of flutes affects the chip load distribution, chip evacuation, and tool engagement with the material. More flutes distribute the load and reduce the force per flute.
Efficiency: Higher flute counts can result in smoother cutting and less vibration, enhancing cutting efficiency.
Flute Shape
Impact: Flute geometry, such as variable helix and variable pitch, influences the stability of the cutter in the material and helps reduce harmonics and chatter.
Efficiency: Flute shapes that optimize chip evacuation and minimize vibration contribute to better surface finish and extended tool life.
How Are Milling Cutters Measured and Described?
Milling cutters are measured using a combination of their diameter and the number of flutes they have. The diameter of a milling cutter is measured from one side of the cutter to the other, passing through the center of the cutter. The number of flutes is the number of cutting edges that are present on the cutter.
In addition to the diameter and the number of flutes, milling cutters are also described by their cutting edge configuration and the material from which they are made. An end mill might be described as a “1/4-inch diameter, 2-flute HSS end mill,” and a ball end mill might be described as a “3/8-inch diameter, 4-flute carbide ball end mill.”
Milling cutters descriptions often include shank type and the type of mounting they use. An end mill might be described as having a “straight shank” or a “weldon shank,” or a face mill might be described as having a “shell mill mounting.”
Milling cutters can also be described by their intended use or the type of workpiece they are designed to cut. For example, a cutter may be described as a “roughing end mill,” a “finishing end mill,”or a “Woodruff cutter.”
When sizing a milling cutter for a particular job, it can make the cut in a single pass if it is large enough to span the entire work surface. If this cannot be done, remember a small diameter cutter will pass over a surface in a shorter time than a large diameter cutter moving at the same speed.
How to Use Milling Cutters?
Step 1: Installing and Setting Parameters
Install the milling cutter onto the milling machine, ensuring it is securely attached and aligned with the machining path.
Next, configure the parameters. Based on the cutting material and type of milling cutter, set the appropriate cutting speed, feed rate, and cutting depth. These parameters significantly impact cutting efficiency and surface roughness, so they need to be confirmed carefully to avoid errors.
Step 2: Fixing the Workpiece and Testing
Secure the workpiece onto the worktable, ensuring it remains stable throughout the machining process to prevent any movement that could affect the cutting results.
Before officially starting the machining, perform a test cut to verify that the set parameters and path are correct. Often, test materials are used to ensure the quality of the final product.
Step 3: Commencing Machining and Post-Processing
Begin the machining process, paying close attention to every detail to avoid oversight and ensure safety.
During milling, cooling methods such as using cutting fluid or compressed air are employed to prevent overheating, which can affect the outcome and prolong the tool's lifespan.
After completion, the finished workpiece is inspected to confirm dimensions and cutting quality. If necessary, subsequent polishing and finishing processes are carried out.
The Considerations for Buying Milling Cutter
Choosing the Right Material
When selecting a milling cutter, the material it's made of is crucial. What type of material are you milling? Is it high-hardness metal or general metal processing? This choice influences whether to use cemented carbide or high-speed steel. Additionally, precision in milling and machining requirements affects the choice of cutter. If detailed shape control isn't necessary, highly precise cutters might not be needed. Cutter size is adjusted based on the material's dimensions and processing method to balance flexibility and efficiency.
Considering Cutting Efficiency
Cutting efficiency is a vital performance indicator for milling cutters. It depends on parameters like cutting speed, feed rate, and cutting depth. The quality of a milling cutter can be evaluated based on its cutting efficiency. A good milling cutter achieves high cutting efficiency without sacrificing precision and surface quality. Poor-quality cutters may suffer from material, design, or manufacturing defects that affect cutting efficiency, potentially causing vibration and instability that affects cutting quality and consistency. Thus, assessing cutting efficiency is essential when choosing a milling cutter.
Seeking Precision
The precision of milling cutter machining significantly influences the quality of produced components. Precision, in this context, refers to the ability to accurately remove excess material according to set cutting paths and dimensional tolerances. A high-precision milling cutter ensures that produced parts are accurate in size, shape, and have a sufficiently smooth surface. A milling cutter lacking precision might result in dimensional deviations, shape distortions, or overly rough surfaces. These defects not only affect aesthetics and tactile feel but also functionality. Parts made with low-precision milling cutters might be rejected due to poor quality, emphasizing precision as a key consideration when selecting a cutter.
Evaluating Wear Resistance
Durability is another indicator of milling cutter quality. Durability directly correlates with whether the cutter can operate continuously over an extended period while maintaining performance, precision, and minimal wear. This factor links directly to production efficiency and cost. High wear resistance means less frequent replacement or adjustment of milling cutters and reflects the cutter's quality and reliability. Evaluating wear resistance is a crucial factor to consider when selecting a milling cutter.
How to Extend the Life of Your Milling Cutter
1. Understand Your Tooling Requirements
It’s important to understand not only what your tool needs, but also general best practices to avoid common machining mishaps. For instance, it is important to use a tool with a length of cut only as long as needed, as the longer a tools length of cut is, the greater the chance of deflection or tool bending, which can decrease its effective life.
2. Consider Variable Helix & Pitch Geometry
A feature on many of our high performance milling cutters is variable helix or variable pitch geometry, which have differently-spaced flutes. As the tool cuts, there are different time intervals between the cutting edges contacting the workpiece, rather than simultaneously on each rotation. The varying time intervals minimizes chatter by reducing harmonics, increasing tool life and producing better results.
3. Ensure an Effective Tool Holding Strategy
Another factor in prolonging tool life is proper tool holding. A poor tool holding strategy can cause runout, pullout, and scrapped parts. Generally, the most secure connection has more points of contact between the tool holder and tool shank. Hydraulic and Shrink Fit Tool Holders provide increased performance over other tightening methods.
4. Run at the Correct Speed
Understanding the ideal speed to run your machine is key to prolonging tool life. If you run your tool too fast, it can cause suboptimal chip size, ineffective chip evacuation, or even total tool failure. Adversely, running your tool too slowly can result in deflection, bad finish, or decreased metal removal rates.
5. Push at the Best Feed Rate
Another critical parameter of speeds and feeds is finding the best possible feed rate for your job, for sake of both tool life and achieving maximum shop efficiency. Pushing your tool too aggressively can result in breakage, but being too conservative can lead to recutting chips and excess heat generation, accelerating tool wear.
6. Use Parameters from Your Tooling Manufacturer
A manufacturer’s speeds and feeds calculations take into account every tool dimension, even those not called out in a catalog and readily available to machinists. Because of this, it’s best to rely on running parameters from tooling manufacturers.
7. Decide On Coolant Usage & Delivery
Coolant can be an extremely effective way to protect your tool from premature wear and possible tool breakage. There are many different types of coolant and methods of delivery to your tool. Coolant can come in the form of compressed air, water-based, straight oil-based, soluble oil-based, synthetic or semi-synthetic. It can be delivered as mist, flood, high pressure or minimum quantity lubricant.
Our Certifications
Our Factory
Hangzhou Wagen Precision Tooling Co.,Ltd is a wholly-owned subsidiary of Ferrotec China Group, a Japanese diversified multinational group. It was established in 2000 with a total investment of 867 million yen. It is a research and development, production and sales of WAGEN brand metal cold saws and aluminum alloy saw blades. , tungsten carbide saw blades and diamond tools and other high-end precision cutting tool products are widely used in automobiles, aircraft parts manufacturing, aluminum alloy profile processing, furniture manufacturing, wood processing, plexiglass processing and other industries.
Ultimate FAQ Guide to Milling Cutter
We're well-known as one of the leading milling cutter manufacturers and suppliers in China. With abundant experience, we warmly welcome you to buy or wholesale high quality milling cutter at competitive price from our factory. Contact us for quotation.
