- Carbide endmill
Carbide End mills
Carbide end mills are essential tools used in milling operations for cutting and shaping various materials. They are highly regarded for their hardness, heat resistance, and versatility. Made from a combination of tungsten carbide particles and a cobalt binder, carbide end mills offer superior durability and wear resistance compared to other types of end mills.
The exceptional hardness of carbide allows it to withstand high cutting forces and maintain its cutting edges for extended periods, resulting in longer tool life. Additionally, carbide’s excellent heat resistance allows these end mills to operate at high speeds and temperatures without compromising their cutting performance.
A wide range of carbide end mill options is available, including various sizes, geometries, and coatings. Different types of end mills, such as square end mills, ball end mills, and corner radius end mills, enable diverse milling operations, including slotting, profiling, and contouring. These tools are used across industries like machining, metalworking, and manufacturing to machine materials like steel, stainless steel, cast iron, aluminum, brass, and plastics.
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Introduction
Carbide end mills are cutting tools used in milling operations to remove material from a workpiece. They are widely used in various industries, including machining, metalworking, and manufacturing. Carbide end mills are preferred over other types of end mills due to their exceptional hardness, high heat resistance, and ability to cut through various materials efficiently.
Carbide is a composite material made primarily of tungsten carbide (WC) particles bonded together with a cobalt (Co) matrix. The combination of tungsten carbide’s hardness and cobalt’s toughness creates a durable and wear-resistant cutting tool. Carbide end mills typically have a cylindrical shank, with cutting edges at one end and a shank for holding in a milling machine at the other.
Composition and Structure
Carbide end mills consist of tungsten carbide particles mixed with a cobalt binder, forming a hard and durable cutting tool. The tungsten carbide provides hardness, while the cobalt binder offers toughness. The grain size and structure of the carbide particles determine the tool’s performance. Additionally, carbide end mills often feature coatings like titanium nitride or diamond-like carbon for improved wear resistance. The end mills have a cylindrical shank, cutting edges with various geometries, and can have different flute designs. Overall, carbide end mills are known for their hardness, heat resistance, and excellent cutting performance.
Hardness
Carbide end mills are extremely hard due to the presence of tungsten carbide particles. This hardness enables them to cut through tough materials like steel and iron with ease.
Wear Resistance
Wear Resistance: Carbide end mills are highly resistant to wear and abrasion. This property allows them to maintain their sharp cutting edges even after prolonged use, resulting in longer tool life.
Heat Resistance
Carbide end mills have excellent heat resistance, which allows them to withstand high cutting temperatures generated during machining operations.
Toughness
While carbide is known for its hardness, the addition of a cobalt binder enhances the toughness of carbide end mills.
Chemical Inertness
Carbide end mills are chemically inert, meaning they are resistant to chemical reactions with most workpiece materials.
Precision
Carbide end mills offer high precision and dimensional accuracy in machining operations. Their hardness allows for sharp cutting edges, resulting in clean and precise cuts.
Versatility
Carbide end mills are versatile tools suitable for a wide range of machining applications. They can effectively cut various materials.
Coatability
Carbide end mills can be coated with various materials. These coatings enhance the tool’s surface hardness, lubricity, and improving performance.
Carbide Material Preparation:
Tungsten carbide powder and cobalt powder are prepared in predetermined ratios and thoroughly mixed to create a homogeneous blend.
Compaction
The blended powders are placed in a hydraulic press and subjected to high pressures to compact them into a solid shape known as a green body.
Pre-Sintering
The green bodies are pre-sintered in a furnace at a specific temperature to remove binders, volatiles, and to strengthen the green body.
Shaping
The pre-sintered green bodies are shaped using various machining techniques such as grinding, cutting, and milling to achieve the desired dimensions and geometries of the end mill.
Sintering
The shaped green bodies are placed in a sintering furnace and subjected to temperatures close to the melting point of cobalt but below the melting point of tungsten carbide.
Tool Body Production
Once the carbide end mill is shaped, it can be coated with various coatings to enhance its performance. Coatings are applied through processes like physical vapor deposition (PVD) or chemical vapor deposition (CVD).
Finishing
After coating, the carbide end mills may require additional finishing processes, such as grinding or lapping, to achieve the desired surface finish and cutting edge sharpness.
QC and Packaging
The finished carbide end mills undergo rigorous quality control inspections. Once approved, they are properly packaged for distribution to customers.
A carbide end mill is a cutting tool used in milling operations. It is typically made from carbide, a composite material composed of tungsten carbide particles bonded together with a binder, such as cobalt. Carbide end mills are known for their exceptional hardness, wear resistance, and heat resistance.
Carbide end mills offer several advantages over other types of end mills. They have a longer tool life due to their high hardness and resistance to wear. Carbide end mills also provide exceptional cutting performance and can maintain sharp cutting edges even at high cutting speeds. Additionally, they are capable of machining a wide range of materials, including metals, plastics, and composites.
Carbide end mills come in various types, each designed for specific machining applications. Some common types include:
- Square End Mills: These have a flat bottom and are used for general milling and contouring.
- Ball End Mills: These have a rounded end and are ideal for machining curved surfaces and 3D contours.
- Corner Radius End Mills: These have a rounded corner and are used for milling rounded edges and corners.
- Roughing End Mills: These are designed for removing large amounts of material quickly.
- Finishing End Mills: These are used for achieving a smooth surface finish on the workpiece.
When selecting a carbide end mill, consider the following factors:
- Material to be machined
- Type of machining operation (e.g., roughing, finishing, profiling)
- Cutting speed and feed rate
- Tool geometry (e.g., number of flutes, helix angle)
- Coating options for enhanced tool life and performance
Consulting with tooling experts or using online resources can help you choose the right carbide end mill for your specific application.
To maximize the lifespan of carbide end mills, follow these practices:
- Use proper cutting speeds and feed rates for the material being machined.
- Use coolant or lubricants to reduce cutting temperatures and improve chip evacuation.
- Avoid excessive vibrations by using proper machining techniques and secure workholding.
- Inspect the end mill regularly for signs of wear or damage and replace when necessary.
Yes, carbide end mills can be resharpened to extend their useful life. However, this process requires specialized equipment and expertise. Resharpening should be done by a professional tool sharpening service to ensure the end mill’s geometry and cutting performance are maintained.
Coated carbide end mills have a thin layer of a coating material, such as titanium nitride (TiN), titanium carbonitride (TiCN), or aluminum titanium nitride (AlTiN), applied to their surfaces. This coating provides additional hardness, lubricity, and heat resistance, resulting in improved tool life and performance compared to uncoated end mills. Uncoated carbide end mills, on the other hand, do not have any coating and are suitable for certain applications where the cutting forces are lower or the material being machined is less abrasive.
Determining the cutting speed and feed rate involves considering factors such as the material being machined, the end mill diameter, and the desired surface finish. Generally, cutting speed is measured in surface feet per minute (SFPM) and can be calculated using the formula: Cutting Speed (SFPM) = (Pi x End Mill Diameter x RPM) / 12. Feed rate, measured in inches per tooth (IPT) or millimeters per tooth (MMPT), can be determined based on the desired material removal rate and the number of teeth on the end mill.
Yes, carbide end mills can be used for both roughing and finishing operations. However, different types of end mills, such as roughing end mills and finishing end mills, are specifically designed for these respective operations. Roughing end mills have a more robust design and are used to remove material quickly, while finishing end mills have a finer pitch and are designed for achieving a smooth surface finish. It’s important to select the appropriate end mill type based on the specific machining requirements.
Yes, safety is crucial when using carbide end mills. Here are a few important safety considerations:
- Wear appropriate personal protective equipment (PPE), including safety glasses, gloves, and hearing protection, to protect against potential hazards.
- Secure the workpiece properly using clamps or fixtures to prevent it from moving during machining.
- Always follow the recommended cutting speeds and feed rates to avoid excessive forces and potential tool breakage.
- Use coolant or lubricants to control heat and remove chips effectively. Be cautious when handling coolant and follow any safety guidelines provided by the manufacturer.
- When changing or handling the end mills, ensure the machine is turned off and take care to avoid any sharp edges or cutting surfaces.
Data
2 Flute End Mills Description
2-flute end mills are versatile tools with two cutting edges. They are used for various machining tasks and can handle a wide range of materials. The flute design aids in efficient chip evacuation and provides a smooth surface finish. These end mills allow for higher feed rates, offer stability, and minimize tool deflection. Choosing the right end mill depends on the specific application and material being machined.
| Type | Dimension (mm) | Number of teeth | ||||
|---|---|---|---|---|---|---|
| D | R | H | L | d | ||
| TMC-2E-D1.0 | 1.0 | / | 3 | 50 | 4 | 2 |
| TMC-2E-D1.5 | 1.5 | / | 4 | 50 | 4 | 2 |
| TMC-2E-D2.0 | 2.0 | / | 6 | 50 | 4 | 2 |
| TMC-2E-D2.5 | 2.5 | / | 8 | 50 | 4 | 2 |
| TMC-2E-D3.0 | 3.0 | / | 8 | 50 | 4 | 2 |
| TMC-2E-D3.5 | 3.5 | / | 10 | 50 | 6 | 2 |
| TMC-2E-D4.0 | 4.0 | / | 11 | 50 | 4 | 2 |
| TMC-2E-D4.5 | 4.5 | / | 11 | 50 | 6 | 2 |
| TMC-2E-D5.0 | 5.0 | / | 13 | 50 | 6 | 2 |
| TMC-2E-D5.5 | 5.5 | / | 16 | 50 | 6 | 2 |
| TMC-2E-D6.0 | 6.0 | / | 16 | 50 | 6 | 2 |
| TMC-2E-D7.0 | 7.0 | / | 20 | 60 | 8 | 2 |
| TMC-2E-D8.0 | 8.0 | / | 20 | 60 | 8 | 2 |
| TMC-2E-D9.0 | 9.0 | / | 22 | 75 | 10 | 2 |
| TMC-2E-D10.0 | 10.0 | / | 25 | 75 | 10 | 2 |
| TMC-2E-D11.0 | 11.0 | / | 26 | 75 | 12 | 2 |
| TMC-2E-D12.0 | 12.0 | / | 30 | 75 | 12 | 2 |
| TMC-2E-D14.0 | 14.0 | / | 32 | 75 | 14 | 2 |
| TMC-2E-D16.0 | 16.0 | / | 45 | 100 | 16 | 2 |
| TMC-2E-D18.0 | 18.0 | / | 45 | 100 | 18 | 2 |
| TMC-2E-D20.0 | 20.0 | / | 45 | 100 | 20 | 2 |
| Type | Dimension (mm) | Number of teeth | ||||
|---|---|---|---|---|---|---|
| D | R | H | L | d | ||
| TMC-2B-D1.0R0.5 | 1.0 | 0.50 | 6 | 50 | 4 | 2 |
| TMC-2B-D1.5R0.75 | 1.5 | 0.75 | 6 | 50 | 4 | 2 |
| TMC-2B-D2.0R1.0 | 2.0 | 1.00 | 6 | 50 | 4 | 2 |
| TMC-2B-D2.5R1.25 | 2.5 | 1.25 | 6 | 50 | 4 | 2 |
| TMC-2B-D3.0R1.5 | 3.0 | 1.50 | 6 | 50 | 4 | 2 |
| TMC-2B-D3.5R1.75 | 3.5 | 1.75 | 6 | 50 | 6 | 2 |
| TMC-2B-D4.0R2.0 | 4.0 | 2.00 | 6 | 50 | 4 | 2 |
| TMC-2B-D5.0R2.5 | 5.0 | 2.50 | 6 | 50 | 6 | 2 |
| TMC-2B-D5.5R2.75 | 5.5 | 2.75 | 6 | 50 | 6 | 2 |
| TMC-2B-D6.0R3.0 | 6.0 | 3.00 | 6 | 50 | 6 | 2 |
| TMC-2B-D7.0R3.5 | 7.0 | 3.50 | 8 | 60 | 8 | 2 |
| TMC-2B-D8.0R4.0 | 8.0 | 4.00 | 8 | 60 | 10 | 2 |
| TMC-2B-D9.0R4.5 | 9.0 | 4.50 | 10 | 75 | 10 | 2 |
| TMC-2B-D10.0R5.0 | 10.0 | 5.00 | 10 | 75 | 12 | 2 |
| TMC-2B-D12.0R6.0 | 12.0 | 6.00 | 12 | 75 | 12 | 2 |
| TMC-2B-D14.0R7.0 | 14.0 | 7.00 | 14 | 75 | 14 | 2 |
| TMC-2B-D16.0R8.0 | 16.0 | 8.00 | 16 | 100 | 16 | 2 |
| TMC-2B-D20.0R10.0 | 20.0 | 10.00 | 20 | 100 | 18 | 2 |
3 Flute End Mills Description
3-flute end mills are cutting tools that are commonly used in milling operations. They are designed with three cutting edges or flutes, which offer several advantages. One of the key benefits of 3-flute end mills is their efficient chip evacuation. The three flutes provide ample space for the chips to evacuate from the cutting area during the machining process. This helps to prevent chip clogging, which can adversely affect cutting performance and result in poor surface finishes. With improved chip evacuation, 3-flute end mills can maintain their cutting efficiency and prolong tool life.
Additionally, 3-flute end mills offer enhanced stability during machining. The presence of three cutting edges provides more support to the tool, reducing deflection and vibration. This increased stability contributes to better dimensional accuracy and surface finish in the workpiece. It also allows for higher cutting speeds and feed rates, resulting in improved productivity. Another advantage of 3-flute end mills is their ability to achieve a smoother surface finish.
3 Flutes Straight Shank Endmills
| Type | Dimension (mm) | Number of teeth | ||||
|---|---|---|---|---|---|---|
| D | R | H | L | d | ||
| TMC-3E-D1.0 | 1.0 | / | 3 | 50 | 4 | 3 |
| TMC-3E-D1.5 | 1.5 | / | 4 | 50 | 4 | 3 |
| TMC-3E-D2.0 | 2.0 | / | 6 | 50 | 4 | 3 |
| TMC-3E-D2.5 | 2.5 | / | 7 | 50 | 4 | 3 |
| TMC-3E-D3.0 | 3.0 | / | 9 | 50 | 4 | 3 |
| TMC-3E-D4.0 | 4.0 | / | 12 | 50 | 6 | 3 |
| TMC-3E-D5.0 | 5.0 | / | 15 | 50 | 4 | 3 |
| TMC-3E-D6.0 | 6.0 | / | 18 | 60 | 6 | 3 |
| TMC-3E-D8.0 | 8.0 | / | 20 | 60 | 6 | 3 |
4 Flute End Mills Description
4-flute end mills are cutting tools with four cutting edges or flutes. They are commonly used in milling operations to remove material from a workpiece. The flute design allows for efficient chip evacuation, reducing the chances of chip clogging and improving cutting performance. The main advantage of 4-flute end mills is their ability to provide a balance of cutting speed and tool rigidity. With four cutting edges, they can achieve higher feed rates compared to end mills with fewer flutes. This results in faster material removal rates and increased productivity.
The additional flutes also distribute the cutting forces across a larger surface area, reducing the tendency for the tool to chatter or deflect during machining. This improves the overall stability of the cutting process and allows for smoother surface finishes.
| Type | Dimension (mm) | Number of teeth | ||||
|---|---|---|---|---|---|---|
| D | R | H | L | d | ||
| TMC-2E-D1.0 | 1.0 | / | 3 | 50 | 4 | 2 |
| TMC-2E-D1.5 | 1.5 | / | 4 | 50 | 4 | 2 |
| TMC-2E-D2.0 | 2.0 | / | 6 | 50 | 4 | 2 |
| TMC-2E-D2.5 | 2.5 | / | 8 | 50 | 4 | 2 |
| TMC-2E-D3.0 | 3.0 | / | 8 | 50 | 4 | 2 |
| TMC-2E-D3.5 | 3.5 | / | 10 | 50 | 6 | 2 |
| TMC-2E-D4.0 | 4.0 | / | 11 | 50 | 4 | 2 |
| TMC-2E-D4.5 | 4.5 | / | 11 | 50 | 6 | 2 |
| TMC-2E-D5.0 | 5.0 | / | 13 | 50 | 6 | 2 |
| TMC-2E-D5.5 | 5.5 | / | 16 | 50 | 6 | 2 |
| TMC-2E-D6.0 | 6.0 | / | 16 | 50 | 6 | 2 |
| TMC-2E-D7.0 | 7.0 | / | 20 | 60 | 8 | 2 |
| TMC-2E-D8.0 | 8.0 | / | 20 | 60 | 8 | 2 |
| TMC-2E-D9.0 | 9.0 | / | 22 | 75 | 10 | 2 |
| TMC-2E-D10.0 | 10.0 | / | 25 | 75 | 10 | 2 |
| TMC-2E-D11.0 | 11.0 | / | 26 | 75 | 12 | 2 |
| TMC-2E-D12.0 | 12.0 | / | 30 | 75 | 12 | 2 |
| TMC-2E-D14.0 | 14.0 | / | 32 | 75 | 14 | 2 |
| TMC-2E-D16.0 | 16.0 | / | 45 | 100 | 16 | 2 |
| TMC-2E-D18.0 | 18.0 | / | 45 | 100 | 18 | 2 |
| TMC-2E-D20.0 | 20.0 | / | 45 | 100 | 20 | 2 |
| Type | Dimension (mm) | Number of teeth | ||||
|---|---|---|---|---|---|---|
| D | R | H | L | d | ||
| TMC-4EL-D3.0 | 3.0 | / | 12 | 75 | 6 | 4 |
| TMC-4EL-D4.0 | 4.0 | / | 15 | 75 | 6 | 4 |
| TMC-4EL-D5.0 | 5.0 | / | 20 | 75 | 6 | 4 |
| TMC-4EL-D6.0 | 6.0 | / | 20 | 75 | 6 | 4 |
| TMC-4EL-D8.0 | 8.0 | / | 25 | 100 | 8 | 4 |
| TMC-4EL-D10.0 | 10.0 | / | 30 | 100 | 10 | 4 |
| TMC-4EL-D12.0 | 12.0 | / | 35 | 100 | 12 | 4 |
| TMC-4EL-D14.0 | 14.0 | / | 40 | 100 | 14 | 4 |
| TMC-4EL-D16.0 | 16.0 | / | 50 | 150 | 16 | 4 |
| TMC-4EL-D20.0 | 20.0 | / | 55 | 150 | 20 | 4 |
| Type | Dimension (mm) | Number of teeth | ||||
|---|---|---|---|---|---|---|
| D | R | H | L | d | ||
| TMC-4R-D3.0R0.2 | 3.0 | 0.2 | 8 | 50 | 6 | 4 |
| TMC-4R-D4.0R0.3 | 4.0 | 0.3 | 10 | 50 | 6 | 4 |
| TMC-4R-D4.0R0.5 | 4.0 | 0.5 | 10 | 50 | 6 | 4 |
| TMC-4R-D5.0R0.5 | 5.0 | 0.5 | 13 | 50 | 6 | 4 |
| TMC-4R-D5.0R1.0 | 5.0 | 1.0 | 13 | 50 | 6 | 4 |
| TMC-4R-D6.0R0.5 | 6.0 | 0.5 | 16 | 50 | 6 | 4 |
| TMC-4R-D6.0R1.0 | 6.0 | 1.0 | 16 | 50 | 6 | 4 |
| TMC-4R-D8.0R0.5 | 8.0 | 0.5 | 20 | 60 | 8 | 4 |
| TMC-4R-D8.0R1.0 | 8.0 | 1.0 | 20 | 60 | 8 | 4 |
| TMC-4R-D10.0R0.5 | 10.0 | 0.5 | 25 | 75 | 10 | 4 |
| TMC-4R-D10.0R1.0 | 10.0 | 1.0 | 25 | 75 | 10 | 4 |
| TMC-4R-D10.0R2.0 | 10.0 | 2.0 | 25 | 75 | 10 | 4 |
| TMC-4R-D10.0R3.0 | 10.0 | 3.0 | 25 | 75 | 10 | 4 |
| TMC-4R-D12.0R0.5 | 12.0 | 0.5 | 30 | 75 | 12 | 4 |
| TMC-4R-D12.0R1.0 | 12.0 | 1.0 | 30 | 75 | 12 | 4 |
| TMC-4R-D12.0R2.0 | 12.0 | 2.0 | 30 | 75 | 12 | 4 |
| TMC-4R-D12.0R3.0 | 12.0 | 3.0 | 30 | 75 | 12 | 4 |
Application Table of Machined Materials
(● perfect suitable ◐ suitable)
| Workpiece | 2 flutes straight shank square endmills | 4 flutes straight shank square endmills | 4 flutes straight shank long flush endmills | 4 flutes straight shank round endmills | 2 flutes straight shank ball endmills | 3 flutes straight shank endmills |
|---|---|---|---|---|---|---|
| Carbon steel | ● | ● | ● | ● | ● | |
| Alloy steel | ● | ● | ● | ● | ● | |
| Hardened steel ∼ 40HRC | ● | ● | ● | ● | ● | |
| Hardened steel ∼ 50HRC | ◐ | ◐ | ◐ | ◐ | ◐ | |
| Hardened steel ∼ 55HRC | ||||||
| Hardened steel ∼ 68HRC | ||||||
| Stainless steel | ◐ | ◐ | ◐ | ◐ | ◐ | |
| Cast iron | ● | ● | ● | ● | ● | |
| Copper alloy | ||||||
| Aluminium alloy | ● | |||||
| Titanium alloy | ||||||
| Heat-resisting alloy |
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