End
Mills & Cutters
Last updated on
Sunday, April 07, 2013 07:45:31 AM
Eastern US Time Zone
End Mills,
Radius Cutters, Saw Blades,
Straight-shank Arbors, ER-16
Collet Extensions, Fly Cutters
End Mills
Center-cutting (left) & non-center cutting (right) type end mills.
Center-cutting end mills can make plunge cuts.
Non-center cutting end mills can not make plunge cuts but clear chips better &
they can be
resharpened easier.
Both types of end mills can make flat surface normal or climb
cuts using the side flutes.
End mill nomenclature
Surface Feet/Minute (SFM) Chart 1
SFM 2
SFM 3
Machinist Calculator
TiN coated, 2 & 4 flute, center-cutting end mill set.
Left to right: 2-flute end mills for aluminum, ball-nose end mills,
45° & 60° dove-tail & bevel cutters, edge finders, 4-flute end mills for steel (regular & roughing).
Had to double the end mill storage
capacity of this stand.
Small diameter carbide drills (left) & small end
mills.
Assorted two, three, & four flute solid carbide end mills sizes ⅜" through
1/32".
1¼", 1", ¾", ⅝", ⅝", ½", ⅜", & ⅜". The three
(right) end mills are M42-8%Co alloy with
extra long cutting flutes.
M42-8%Co alloy cutting mildly hardened steel.
⅛" & ¼"
diameter, center
cutting, long (4) flute,
Titanium Aluminum Nitride
(TIALN) coated end mills.
¼", 5/16", ⅜", ½", & ⅝" roughing end mills. Sinusoidal-edge pattern breaks
chips.
Note: aggressive cuts with this design can overload smaller
machines.
Metric carbide end mills: 1, 2, 3, & 4 mm.
1 & 2 mm end mills.
3 & 4 mm end mills.
Two-flute ball-nose end mill. There are also 3 & 4 flute types.
These cutters like higher speeds.
1/32", two-flute ball-nose
carbide end mills.
Dovetail cutters; 45° (top) & 60° (bottom). Cut a square
groove, first.
45° (left) & 60° (right)
bevel cutters (import). For chamfering part edges.
Bin sorting & storage of end mills.
One-inch "Little Hogger" negative-rake end mill
with a ¾" shank that uses two, TNMG
inserts.
TNMG
inserts have six usable tips, each.
This end mill requires relatively high RPM.
½" cobalt end mill with 45° point. Handy for chamfering edges.
Radius Cutters
Radius cutter set. 1/16", 3/32", ⅛", 5/32", 3/16", ¼", 5/16", & ⅜" radii.
⅛", 30º carbide engraver bit.
Solid carbide engraving tools for the
CNC mill. The end was first split in
half with a standard
surface
grinder then the tip was diamond ground to have relief behind the single-flute
cutting edge.
The
point
was then relieved even more using a fine diamond file.
See the high-speed
motor pulley modification.
Saw Blades
A 45º, left-hand cutter & 3" saw blades with 1" hole having different
thicknesses of 1/16",
1/32", & 1/64".
Slit-cutting soft steel. The
right side of the vise has a spacer piece of equal thickness to assure even
clamping.
This is a one-inch R8 arbor.
Straight-shank Arbors
Precision ground ⅞" x 1" arbor with a ¾" straight
shank.
Spring-loaded rings spacers
for different saw hole sizes: ½", ⅝", ¾", ⅞", & 1" (India).
Below average quality.
ER-16 Collet Extensions
When changing tooling that has different lengths, e.g.,
a
collet chuck versus a fly cutter,
I do not want to
have to loosen/move the mill head & then re-indicate the piece.
A stubby
ER-16 collet extension & a short-
arbor drill chuck allow me to stay close to the
work piece. The long ER-16 extension allows
the use of longer
tooling & end mills. Additionally, the long extension can get into much tighter places than the mill
spindle.
ER-16 collet extension pair (US) having stubby (3.65") & long (6.3"),
¾" diameter shanks. These are very
precisely made extensions with a collet lock nut 13/16"
&
there is an inside back-up hex setscrew with
left-hand
threads that is set against the end mill base. The Martin Tools
open-end wrench is thinner, flatter & shorter than
a standard type making it easier to use
in tight areas. The collet is snapped into the nut before tightening.
The extensions are made by
Craftsman Industries in NV.
CAUTION: Do not over tighten lock nut, always use internal backup screw. Do not tighten lock nut on an empty collet.
Stubby extension stays close to the work & can use 10 different ER-16 collet sizes with a 0.0197"
~
0.3937"
(0.5 ~ 10mm) continuous clamping range. This is especially helpful when using combinations of drills & end mills.
The long extension helps machine hard to access areas.
Fly Cutters
Fly cutter (Sierra American Brand, USA)
with ¾" straight shank & ⅜" USA Carboloy grade, left-hand tool bit.
This combination has superior cutting performance when compared to many imports.
It is balanced, precise & rigid plus the setscrews are hardened & don't strip.
Fly cutter set with straight shanks (import). Substituting with quality setscrews helps performance.
Fly cutter with a ⅜" straight shaft which is the right size for use in the
upgraded ER-16 mill spindle.
End Mills,
Radius Cutters, Saw Blades,
Straight-shank Arbors, ER-16
Collet Extensions, Fly Cutters