Milling Cutters

Milling is a process conducted in machining, where the machine spindle holds a milling tool holder, which then holds a cylindrical milling tool. Milling tools are used to perform milling operations in machining where swarf from the workpiece is removed either directly from the shape of the milling cutter or by their own movement within the machine.

There are many features of a milling cutter as they are available in different shapes and sizes and are manufactured for general purpose or specific machining tasks. The following are variable features of milling cutters: Shape – In today’s machining industry, solid carbide milling cutters are produced in several standard shapes. Teeth/Flutes – The flutes of the solid carbide milling cutter run up the cutter and are deep helical grooves, and the tooth is a sharp blade that runs on the flute’s edge and is designed to cut away the workpiece. Due to the rotary movement, remnant material (swarf) is then pulled up the cutting edges of the flute.  Two, three, or four is the most common number of teeth for a milling cutter, and usually, more teeth can remove materials quicker. Helix Angle – Milling cutters are usually helical as vibration is reduced when the tooth gradually contacts the material. To result in a better finish, finishing cutters have a higher rake angle. Centre Cutting – Some have teeth that do not meet at the end face centre, so these cannot plunge through materials, whilst others can. At roughly a 45-degree angle, these cutters can cut in a downward motion. Roughing or Finishing – Roughing is when a lower-quality surface finish is achieved by using a solid carbide milling cutter to remove increased amounts of material. If a roughing end mill is needed to break down material into smaller pieces, it may have serrated teeth which leave a rough finish. Finishing is when a higher-quality surface finish is achieved by removing less material. These types of cutters may remove aluminium and other materials more precisely due to the large number of teeth. Coatings – Tool coatings can ascertain increased tool life, cutting speed, and surface finish. There are various different coatings that can be used, with different coatings being better suited to different materials being cut. For a tool required to withstand higher abrasive wear, PCD (Polycrystalline diamond) can be used which can offer exceptional tool life, increased up to 100 times when compared with uncoated. Each various coating we offer at Sutton Tools UK has its benefits which is why our technical engineers are on hand to advise on a coating to best suit your milling cutters and provide you with increased tool life. Shank – The cylindrical part of the tool that is held in the holder is called the shank. A shank can have a Weldon Flat, where contact from a set screw increases torque, or it can be round and held by friction. Sutton Tools UK manufactures and distributes high-performance milling cutters manufactured from solid carbide so that you can achieve high speed and high feed milling. You will find products in our FENN range suitable for machining aluminium, steel (stainless steel and alloy steels), and cast iron.