End Mills

End mills are versatile cutting tools used in milling machines for machining various materials, typically metals, plastics, and composites. They feature a rotating cylindrical shape with cutting edges on the sides and/or the end. Here are the key aspects of end mills:

1. Types:

   • Square End Mills: These have flat tips and are ideal for making precise cuts, such as drilling straight pockets, holes, and slots.
   • Ball Nose End Mills: Featuring a rounded tip, these are used for contouring and profiling complex 3D shapes, often in mold making.
   • Roughing End Mills: Designed for aggressive material removal, they have serrated teeth to break up material before finishing cuts.

2. Cutting Surfaces: Most end mills cut on the side and bottom. Some specialized designs, like single-flute end mills, cut only on one side.

3. Material: Common materials include high-speed steel (HSS), cobalt, carbide, and coated varieties. Carbide end mills are popular for their hardness and durability, ideal for high-speed cutting.

4. Flute Design: The flutes, or grooves on the tool, facilitate chip removal and cooling. The number of flutes (typically 2, 3, 4, or more) impacts the tool’s cutting speed, material removal rate, and surface finish.

5. Applications: End mills are used for tasks like drilling, slotting, contouring, and even surface finishing. They are used in industries like aerospace, automotive, mold making, and metalworking.