Ball Nose Cutter And End Mill

There are many types of milling cutters. The most common standard rubber in our lives has drilled steel bars. Drilling wooden freestanding cabinet, professional bathroom vanity, and the slate heart photo frame hanging on the wall, johnson glazed ceramic wall tiles, etc., but for curved surfaces, special-shaped surfaces, and inclined surfaces, you need to choose a ball nose cutter.

 

Ball nose cutter

 

It is widely used in the processing of various structural shapes such as the side surface, forming surface and groove of the machined parts. The main structural parameters of the milling cutter include the number of teeth, helix angle, groove depth, rake angle, end tooth, and peripheral tooth clearance angle. Among them, the spiral chip flute geometry is the most critical factor of the tool's geometric angle. Whether the geometry of the flute is reasonable or not directly affects the tool life, smooth chip evacuation, and machining accuracy.

 

Now CNC tool grinders grinding the spiral grooves of end mills have become the main process, replacing the traditional forming milling grooves. The main factors that determine the shape of the groove are the surface, groove depth and rake angle of the rotating grinding wheel used for grinding the tool. Generally, for cutting brittle materials or high hardness, the groove depth is shallower; for plastic materials, the groove depth is deeper. End mills are classified into ball end mills, right angle end mills and arc end mills according to the type of cutter head. Right-angle end milling cutters are used for processing groove sides, etc., spherical milling cutters are used for forming and profiling processing, etc., and ball end milling cutters are used for processing side surfaces with a corner R.

 

Two advantages of ball-end knives

 

The stability during cutting, only the center point of the tool is stressed during processing, and it is not easy to produce chatter.

 

The most important advantage is that if you use an ordinary flat-bottom milling cutter to mill the surface, although the processing efficiency is high, the remaining material steps are unacceptable. If you use a ball cutter, this problem can be solved and a better surface finish can be obtained. That is why the milling surface is roughened with a common milling cutter, and finally finished with a ball cutter.

 

The manufacturing requirements of milling cutters are high and difficult. Let's look at the following manufacturing process of ball end milling cutters.

 

Manufacturing process of ball nose cutter

 

The manufacturing process of the milling cutter includes several parts such as the selection and parameters of the grinding wheel, the geometric design of the cutter, the setting of the machining parameters of the machine tool, and the analysis of the grinding path.

 

When machining a ball-end milling cutter, the process is divided into 7 steps: cutting (cutting), Flute (spiral flute), Gashing (chip flute), Face2 (end tooth second relief angle), Face1 (end tooth first) Back angle), OD2 (second back angle of peripheral teeth), OD1 (first back angle of peripheral teeth)

 

Matters needing attention when manufacturing knives

 

(1) Ensure the reliability of tightening and position accuracy.

 

(2) Input the tool geometry parameters in the Quinto software user interface:

 

4 flute equally divided flute 4, cutting edge length 49, helix angle 29°, cutter tooth depth 2, end teeth first clearance angle 9°, end teeth second clearance angle 19°, peripheral teeth second clearance angle 29°, The first clearance angle of the circumferential teeth is 8°, the arc radius is R1, the rake angle is 14°, and right-handed.

 

Nice ball nose cutters you can choose from here

 

45HRC carbide 2flutes ball nose

 

1. Tolerance of Endmill （Diameter accuracy tolerance）

D1-D6 -0.01~0.03

D6-D10 -0.015~-0.04

D10-D20 -0.02~-0.05

2. Parameters （Recommend）

Cutting speed： Vc = 220 (120-180)m/min

Cut deep： ap = 1/3D(1/8-1/2D)

Cut width： ae = 1/2D(1/4-1D)

Single edge feed： fz = 0.15mm(0.02-0.2)

3. Workpiece Material(Recommend）

（1）Carbon Steel

（2）Alloy Steel

（3）Cast Iron

（4）Hardened Steel

4. Coating

TiSiN

5. Helix Angle

35

 

65HRC carbide 2flutes ball nose

 

1. Tolerance of Endmill （Diameter accuracy tolerance）

D1-D6  -0.01~0.03

D6-D10  -0.015~-0.04

D10-D20 -0.02~-0.05

2.Parameters （Recommend）

Cutting speed：Vc = 130 (120-180)m/min

Cut deep：ap = 1/3D(1/8-1/2D)

Cut width：ae = 1/2D(1/4-1D)

Single edge feed：fz = 0.15mm(0.02-0.2)

3. Workpiece Material（Recommend）

（1）Carbon Steel

（2）Alloy Steel

（3）Cast Iron

（4）Hardened Steel

4.Coating

AITiSiN

5.Helix Angle

35

 

End mill

 

Speaking of the scope of processing, nowadays, CNC tools have gradually become domestically produced. Especially in the field of solid carbide end mills, 5 axis cnc machining services requires milling cutters in many workpieces It's getting higher and higher. It has been developed in the direction of simplification, that is, to reduce the number of styles and use as little as possible, which means that one forming cutter cutter can replace 2 to 3 cutters or even more. So what is the processing range of the end mill?

 

End mill processing range

 

End mills can generally be used to process planes and side mills. If it is a ball nose cutter, it can also be used for 3D milling service for processing 3D surfaces.

 

Applicable material range of end mills

 

Commonly used to process steel parts such as die steel, titanium alloy, aluminum alloy, copper alloy, high temperature alloy, powder metallurgy, cast iron, stainless steel, and 45# steel. There are also milling cutters suitable for processing non-metals and special metals such as nickel-chromium alloys.

 

Choose an end mill

 

The following three points are used to select the end mill

 

1. Choose the type of tool coating according to the hardness and type of the workpiece

 

For example, when processing carbon steel and other workpieces whose hardness is below HRC40, MIRACLE40 coating can be used. When processing tool steel, alloy steel S and other workpieces with a hardness of about HRC50, MIRACLE coating can be used. When processing workpieces with higher hardness, hard alloy materials can be selected. The tool shape and coating are all MIRACLE coatings for high hardness processing dedicated to processing high hardness materials.

 

2. Choose the shape of the end mill neck according to the shape of the workpiece

 

The neck shape of the ball end mill is divided into standard type, long neck type and tapered neck type, which can be selected according to the processing depth and shape of the workpiece. Long-neck type and tapered-neck type can be deep-cut. When choosing between the two, the interference angle should be considered. At the same time, compared with the long neck type, the tapered neck end mill has higher rigidity, which can improve the cutting conditions and achieve better machining accuracy. The tapered end mill should be selected as far as possible.

 

3. Choose end mills with different ball head accuracy according to the processing accuracy.

 

The arc accuracy of ball end mills is usually ±10μm, but there are also ±5μm high-precision end mills, which can be used for high-precision machining.

 

Any interests in ball nose cutter and end mill, welcome  to contact us.