Zone: Milling Tools

Taking The Plunge

It doesn't take sophisticated technology to perform plunge roughing effectively. In fact, if you are making due with a less effective machine, plunge roughing deserves even more serious consideration. (Includes video.)

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The Key Points Of Helical Holemaking

VIDEO. Have you considered milling holes through helical ramping instead of drilling them? This brief animated video covers the high points, including tool diameter selection and the potential for savings.

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How & Why You Should Consider CNC Tool Grinding

If you outsource tool grinding or grind tools manually, this webinar is for you. Simon Manns explains WHY some shops move to CNC tool grinding. He then covers things to consider IF that move makes sense for you. Topics include

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Tools Can Drill, Thread, Chamfer All at Once
2/6/2012 Modern Machine Shop: Carmex Precision Tools’ DMT line of thread milling tools enables customers to drill, thread and chamfer in a single operation.
Insert Geometry Doubles Hard Milling Throughput
11/10/2011 Modern Machine Shop: Insert geometry can make a huge difference in throughput, as demonstrated by the gains this manufacturer realized by swapping tools in a long-reach slot-finishing application in hardened tool steel.
Video: Milling Inconel 718 with Cermic Inserts
10/24/2011 Modern Machine Shop: Metal removal rate is high and the cut is dry. See other basic tips for milling with ceramics.
How Micromachining Patience Speeds Prototype Production
10/12/2011 Modern Machine Shop: A molder of tiny, silicone components for the medical industry explains how a patient, conservative approach to micromachining enables it to deliver prototypes faster.
Milling HRSAs: The Checklist
8/12/2011 Modern Machine Shop: When milling super alloys, there are certain process requirements that must be observed.

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Overview Of:
Milling Tools

Milling is the work of producing a flat or precision-contoured surface on a machined workpiece by using a rotating tool, and generally by taking multiple parallel passes with that tool. The work can be done on a machining center or milling machine, and can also be done on a lathe, turning center or turn-mill machine that happens to have rotary tool (or “live tool”) capabilities. The tools for milling include both solid tools and inserted tools—the latter consisting of a tool body that uses replaceable cutting inserts. Carbide is the most likely material for milling tools, though high speed steel is another choice, as are ceramic, cermet and diamond tools in certain more demanding milling applications. A common milling tool variety is the “end mill,” which generally describes a relatively narrow cylindrical tool that can mill on both its tip and its side, and can reach into various constrained features and spaces. The end mill can be flat-bottomed for flat surfaces, or ball-nosed for milling up, down and along the contours of complex milled shapes such as die and mold surfaces. Another common milling tool variety is the “face mill,” a generally larger-diameter tool designed for efficiently milling a wide, flat surface in an economical number of passes.