Introduction
Milling is a machining process commonly used in manufacturing industries to cut and shape a variety of materials. The milling process involves rotating a cutting tool, called a milling cutter, along one or more axes to remove material from the workpiece. The cutting edges of the milling cutter are the most important part of the tool as they make the actual cuts. In this article, we will discuss what the milling cutting edges are called and their types, shapes, and applications.
Milling Cutting Edges Types
Milling cutters can be classified into various types based on their cutting edges. The most common types of milling cutters based on their cutting edges are as follows:
1. Solid Carbide
Solid carbide cutters are made from a single piece of carbide material. The cutting edges are formed by grinding the carbide material into the required shape. Solid carbide cutters are incredibly strong and can cut through hard materials like steel and titanium. They are ideal for high-speed milling operations and provide excellent surface finishes.
2. High-Speed Steel (HSS)
High-speed steel cutters are made from a high-speed steel material. The cutting edges are formed by grinding the steel material into the required shape. HSS cutters are versatile and can cut through a variety of materials, including aluminum, brass, and cast iron. They are the most common type of milling cutter used in manufacturing.
3. Cobalt Steel
Cobalt steel cutters are made by adding cobalt to the high-speed steel material. The cutting edges are formed by grinding the cobalt steel material into the required shape. Cobalt steel cutters are ideal for cutting harder materials like stainless steel and hard steel alloys.
4. Diamond-Coated
Diamond-coated cutters have a diamond coating applied to the surface of the cutting tool. The diamond coating provides exceptional hardness and durability, allowing them to cut through materials that other cutters cannot. These cutters are commonly used in the aerospace and medical industries.
Milling Cutting Edges Shapes
The shape of the milling cutter''s cutting edge determines the type of cut it can make. The most common shapes of milling cutting edges are:
1. Helical
Helical cutting edges have a spiral shape that wraps around the milling cutter. These cutters are ideal for making cuts on steep slopes and have a higher removal rate compared to other shapes.
2. Ball-Nose
Ball-nose cutting edges have a rounded shape that is useful for creating contours and 3D shapes on the workpiece. They are often used for finishing operations and are especially useful when making curved surfaces.
3. Corner-Rounding
Corner-rounding cutting edges have a radius on the corner that allows them to create fillets on the workpiece. These cutters are useful for making rounded corners and improving the overall appearance of the workpiece.
4. Face
Face cutting edges are flat and are used for making flat-bottomed cuts. These cutters are ideal for roughing operations and removing large amounts of material quickly.
5. Chamfer
Chamfer cutting edges have an angled shape that allows them to create a beveled edge on the workpiece. These cutters are commonly used in woodworking and metalworking.
Milling Cutting Edges Applications
The milling cutting edges can be used for a wide range of applications. Here are a few examples:
1. Roughing
Roughing operations involve removing large amounts of material from the workpiece quickly. For this type of operation, cutters with large helical cutting edges or face cutting edges are ideal.
2. Finishing
Finishing operations involve smoothing the surface of the workpiece after the roughing operation. For this type of operation, cutters with ball-nose cutting edges or corner-rounding cutting edges are ideal.
3. Slotting
Slotting operations involve making narrow cuts on the surface of the workpiece. For this type of operation, cutters with straight cutting edges are used.
4. Drilling
Drilling operations involve making holes in the workpiece. For this type of operation, cutters with pointed cutting edges, also known as drills, are used.
5. Contouring
Contouring operations involve creating 3D shapes on the surface of the workpiece. For this type of operation, cutters with ball-nose cutting edges or corner-rounding cutting edges are ideal.
Conclusion
In conclusion, the cutting edges of milling cutters are the most important part of the tool as they make the actual cuts. The cutting edges can be classified into various types based on their material and shape. The shape of the cutting edge determines the type of cut it can make, and the applications of milling cutting edges range from roughing to contouring. Understanding the different types and shapes of milling cutting edges is essential for choosing the right cutter for the job.