Operations
- Max Boone
- Casey Sauer
Types of End Milling
There are multiple ways to cut with an endmill that all require different geometric considerations to generate an accurate cut with an acceptable level of tool wear.
Profile
Profiling is taking material away from the sides, specifically on the peripheral of the part. This is the most efficient method of cutting with an endmill and also produces the least amount of tool wear.
Pocketing is taking away material in a profile, but on the inside of a part. There are three main ways the endmill gets to the inside of the part: helical ramping, linear ramping, and predrilling.
Helical Ramping - Endmill cuts downwards by ramping in a tight circle, once it gets to the desired depth it will cut sideways into the rest of the pocket
Linear Ramping - Endmill cuts downwards by ramping in a straight line or curve following the pocket’s profile, once it gets to the desired depth it will cut sideways into the rest of the pocket
Predrilling - Drill a hole slightly larger than the endmill to the bottom of the pocket, then the endmill lowers down into the hole and then cuts sideways into the rest of the pocket
Slot
Slotting is when an endmill takes away material at full thickness. This loads the tool much more than other operations and requires slower and more gentle toolpaths.
Contour
Contouring creates 3D shapes. It is usually done with a radiused endmill (either bullnose or ball end), as this technique can be rough on the sharp edges of a flat endmill.
Holemaking
Drill
Drilling involves sending a drill straight down into the part to create a hole. There are a few different types of drills that are used for different purposes: twist drills, spot drills, and center drills. Starting a hole by spotting with a spot drill or center drill helps to keep the long drill from walking when entering, resulting in a more accurate hole location and less tool wear.
Twist Drill - The typical drill bit that cuts a hole.
Spot Drill - A very stubby drill bit used to start a hole. Usually better than center drills, but more expensive.
Center Drill - A very stubby drill bit used to start a hole. Designed to create a hole good for a live center on a lathe. Usually cheaper than spot drills.
Reamer
Reaming expands a hole made by a drill to a precise diameter (below 0.001”). Reamers require a predrilled hole. Reamers are made to be long and flexible so that they follow the path of a hole.
Thread
Threadmilling is a way of creating threads in a hole or externally on a boss without having to use a tap or die by hand. The threadmill will spiral in the shape of the threading, taking a little but away in each successive pass. This can be used for large threads that are annoying to tap or for threads that need to be extremely concentric.