Carbide End Mills for Aluminum

Why choose Us

Wide Range of Applications

Our company mainly produces solid carbide milling cutters, drill bits, engraving tools, and various non-standard tools. Products are widely used in mold, aviation, electronics, advertising, home furnishing and other industries.

One-Stop Service

We provide one-stop service from design, manufacturing to delivery. At the same time, in order to meet the needs of different customers, the company's professional technical staff will provide customers with customized services.

Advanced Technical Equipment

The company gives priority to the introduction of advanced manufacturing and monitoring equipment, such as the Swiss WALTER CNC milling cutter grinder and the German EOUER tool testing equipment, which greatly improves the company's manufacturing capabilities and product quality.

Recognition From Global Customers

After years of development, the GR8 brand has successfully expanded into markets in more than 50 countries including Japan, Australia, Asia, the Middle East, Europe, and the Americas, and has been recognized by more and more customers.

What is Carbide End Mill for Aluminum?

Due to the relative softness of aluminium, specific characteristics and geometries in solid carbide end mills are required for efficient machining of this ductile material.

Carbide end mills are mainly used on milling machines and drilling machines. They are mainly used to cut hard materials or materials that are difficult to machine. One of the characteristics of cemented carbide is it is extremely hard. Tungsten carbide is an alloy made by sintering hard metal carbide powder with iron-based metal powder. There are various shapes of cutting edges, but mainly two-flute and four-flute spiral shapes are commonly used.

Material of Carbide End Mill

Let’s begin with the substance from which carbide end mills are constructed. The substance is not solid metal but rather a tungsten carbide matrix (which consists of equal parts tungsten and carbon) bound together by a binder, often cobalt. In addition, a skinny coating may be applied to the end mill to improve performance further.

As expected, the tungsten carbide and not the binder are responsible for most of the cutting. Therefore, a significant proportion of the carbide’s quality is dependent on the ratio of tungsten carbide grains to the binder. Cheap carbide contains far more binder than high-quality carbide. This may be caused by the way the material is processed or the grain size.

Benefits of Carbide End Mills for Aluminum

Improved Chip Evacuation

The corrugated design of the end mill helps in breaking the chips into smaller pieces and guiding them away from the cutting area. This reduces the risk of chip buildup.

Higher Material Removal Rate (MRR)

The wavy edge geometry allows for more effective engagement with the workpiece, enabling higher feed rates and increased material removal rates. This can lead to faster machining times and higher productivity.

Longer Tool Life

The reduced vibration, effective chip evacuation, and improved cooling contribute to a longer tool life compared to traditional end mills, leading to reduced tooling costs over time.

Optimized Surface Finish

The unique cutting action of corrugated carbide end mills can lead to improved surface finishes, reducing the need for secondary finishing operations and saving time.

Adaptability to High-Speed Machining

The design of corrugated carbide end mills, combined with their ability to efficiently evacuate chips and manage heat, makes them suitable for high-speed machining applications, where maintaining consistent performance and surface finish is important.

Types of Carbide End Mill

Square End Mills

Square end mills are used for general milling applications including slotting, profiling and plunge cutting.

Keyway End Mills

Keyway end mills are manufactured with undersized cutting diameters to produce a tight fit between the keyway slot they cut and the woodruff key or keystock.

Ball End Mills

Ball end mills, also known as ball nose end mills, are used for milling contoured surfaces, slotting and pocketing. A ball end mill is constructed of a round cutting edge and used in the machining of dies and molds.

Roughing End Mills

Roughing end mills, also known as hog mills, are used to quickly remove large amounts of material during heavier operations. The tooth design allows for little to no vibration, but leaves a rougher finish.

Corner Radius End Mills

Corner radius end mills have a rounded cutting edge and are used where a specific radius size is required. Corner chamfer end mills have an angled cutting edge and are used where a specific radius size is not required. Both types provide longer tool life than square end mills.

Roughing and Finishing End Mills

Roughing and finishing end mills are used in a variety of milling applications. They remove heavy material while providing a smooth finish in a single pass.

Corner Rounding End Mills

Corner rounding end mills are used for milling rounded edges. They have ground cutting tips that strengthen the end of the tool and reduce edge chipping.

Drill Mills

Drill mills are multifunctional tools used for spotting, drilling, countersinking, chamfering and a variety of milling operations.

Tapered End Mills

Tapered end mills are designed with a cutting edge that tapers at the end. They are used in several die and mold applications.

The Significance of End Mill Coating

The coating is a critical step that permits carbide end mills to withstand wear. Coatings help the cutting tool evacuate chips from the flutes quicker, removing the HOT chips from the ground surface of the end mill. Carbide is not a friend of heat. In the last ten years, the development of more heat- and wear-resistant coatings has boosted tool durability and productivity.

The Functions of Coating Include:

Increase the difficulty.
Enhance lubrication.
Offer enhanced chip evacuation.
Provide thermal insulation.
Enhance the surface’s finish
Decrease abrasive wear
Extend the tool’s useful life.

Applications of Carbide End Mills in Different Industries

Mold processing

Die and mold manufacturing is a specialist field that needs both common and specialized equipment, notably milling cutters, to allow the manufacture of small batches for particular uses. Metal removal rates from carbide end mills with the proper cutting geometry and coatings can be four to five times greater than those from moulded steel.

Heat-Resistant Alloy Machining

One of the numerous uses for this tool, which also serves a variety of other objectives, is the machining of heat-resistant alloys like titanium, stainless steel, and other materials. Some end mills can be used in processes that are carried out at high temperatures because they have a surface that is much more abrasive.

3C Processing

Aluminum and plastics are the two materials most frequently utilized in the 3C sector. Glass, ceramics, and stainless steel have now been included. End mill providers have significant demands as a result of the intense competitiveness in the 3C industry, which necessitates both quick delivery and exceptionally long tool lives.

Aviation Industry

In the aviation sector, milling is widespread. For the components of aircraft wings and engines, complex end mills are employed. In the aviation sector, end mills are now one of the most crucial machining techniques, particularly when working with aluminum alloys.

Metal Manufacturing

A highly sharp cutting edge and a tiny radius are only two of the properties that make carbide end mills excellent for use in metalworking operations including turning, milling, drilling, and tapping. For many metal production applications, carbide end mills provide a reliable and long-lasting option.

Guide to Selecting an End Mill for Aluminum

DLC Coating U Slot End Mill for Aluminum

Geometry

The geometry of the end mill typically refers to its basic shape and design. The shape you choose will typically depend on the nature of the machining you want to do, and not the material itself. Besides general shape, various tooling options are also available for end mills. Chipbreaker tools, for instance, improve chip evacuation. Off-set chip breaker geometry reduces chip size for enhanced evacuation while leaving workpiece surfaces semi-finished.

Coatings

Coatings are end mill bit finishes designed to increase hardness, reduce abrasive wear, prolong the tool’s life, and create a thermal barrier between the bit at the workpiece. Some coatings may also improve waste material evacuation, reducing friction damage further. However, coating materials suitable for use with aluminum are minimal. Because aluminum is a soft metal, end mill coatings do not need to provide much additional hardness.

Flutes

When it comes to choosing end mills for aluminum machining, flutes are perhaps the most important consideration. They remove aluminum chips from workpieces, preventing them from cluttering the material. The number of flutes an end mill has determines its rigidity, chip evacuation capacity, wear time, vertical accuracy, and performance on both soft and hard materials. Generally speaking, the more flutes, the more rigid the bit is. However, chip evacuation performance goes down.

Angle

The helix angle is the angle between the mill’s centerline and the tangent of its cutting edge. End mills with shallower angles have cutting edges that coil around them more slowly than those with higher angles. Helix angles matter a great deal for aluminum machining. For aluminum cutting, machinists typically use 45°, 50°, and 55° helix angles. These tend to generate the least chatter and offer the best balance between rigidity and chip extraction. Some professionals may choose to use variable helix angle bits for more reliable operation when drilling at depth.

Tips for Extending the Lifespan of Carbide End Mill

Choosing the Right End Mill for Your Application

Choosing the right end mill for your application involves considering factors such as the material being machined, the desired surface finish, the type of machining operation, and the cutting speed and feed rate. Using the wrong end mill can lead to premature wear and tear and poor machining results, reducing the tool’s lifespan.

Proper Maintenance and Cleaning Techniques

After each use, it’s essential to clean the end mill thoroughly, removing any chips, coolant, or debris that may have accumulated on the tool. Leaving chips or coolant on the end mill can cause corrosion and lead to premature wear and tear.

The Importance of Speed and Feed Rates

High cutting speeds and feed rates can cause excessive heat and stress on the end mill, leading to premature wear and tear. On the other hand, low cutting speeds and feed rates can cause the end mill to rub against the material, leading to dulling of the cutting edges. Using the right cutting speed and feed rate will help prevent premature wear and tear and extend the lifespan of your end mill.

Common Mistakes to Avoid While Using End Mills

Several common mistakes can lead to premature wear and tear of your end mill. One of the most common mistakes is using the wrong cutting speed and feed rate for your application, as we discussed earlier. Another mistake is using a worn-out end mill or one with damaged cutting edges, leading to poor machining results and further damage to the tool.

Our factory

Introducing the most advanced production technology and the most advanced CNC tool production equipment at home and abroad, we use our process optimization methods to improve production quality, reduce costs and increase productivity.

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Our certificates

We have passed ISO 9001 quality management certification and obtained various qualification certificates, and are committed to providing customers with high-quality products.

Frequently Asked Questions

Q: Can you use carbide end mill on aluminum?

A: The biggest downside to this type of end mill for your CNC is that they can get pricey. Or at least more expensive than high-speed steel. As long as you have your speeds and feeds dialed in, carbide end mills will not only cut through aluminum like butter, but they will also last quite a while.

Q: Can carbide be used on aluminum?

A: Because cutting aluminum requires higher RPMs, high-speed steel and cobalt are not likely to be enough for the job. Because of its higher degree of brittleness, carbide is an excellent choice for use in carbide inserts for aluminum manufacturing. In order to achieve faster machining rates, smaller diameter carbide for aluminum are required. Another advantage of this situation is that the stiffness of the carbide will defend against any tool deflection that may occur.

Q: What is the best end mill for aluminum?

A: With higher flute counts, it would become difficult to evacuate chips effectively at the high speeds at which you can run in aluminum. This is because aluminum alloys leave a large chip, and chip valleys become smaller with each additional flute on an end mill. Traditionally, 2 flute end mills have been the preferred choice for Aluminum.

Q: Can solid carbide cut aluminum?

A: Carbide-tipped saw blades are versatile cutting tools that can be used with a variety of machines to cut aluminum and other materials. When it comes to aluminum cutting, the choice of machine will depend on the thickness of the material, the type of aluminum alloy, and the specific application.

Q: What RPM should you mill aluminum?

A: Instead, any milling process run at around 15,000 rpm or higher is likely to offer some optimum spindle speed, a "sweet spot," where the cut is significantly more stable than it is at both higher and lower speed settings.

Q: What is a carbide end mill?

A: Carbide end mill bits are solid round milling cutters used for applications such as slotting, profiling, face milling and plunging. See our carbide end mill speeds and feeds chart for parameters specific to your material.

Q: What is the best end mill for carbon steel?

A: Primarily, carbide end mills work best for steel and its alloys because it has more thermal conductivity and works well for hard metals. Carbide also operates at higher speed, which means your cutter can withstand higher temperatures and can prevent excess wear and tear.

Q: What is the purpose of the end mill?

A: End Mills are used for making shapes and holes in a workpiece during milling, profiling, contouring, slotting, counterboring, drilling and reaming applications. They are designed with cutting teeth on the face and edge of the body and can be used to cut a variety of materials in several directions.

Q: Why is carbide good for milling?

A: Carbide end mills are the most commonly used tool for milling operations, and for good reason. These cutting tools are able to remove material quickly and efficiently, resulting in a smooth and accurate finish. Carbide end mills can also handle a wide range of materials, including aluminum, steel, and titanium.

Q: Is carbide harder than steel?

A: Carbide has all but replaced steel tooling in recent years. Carbide is much harder than steel and much more resistant to heat. Although a carbide-tipped tool is more expensive than a comparable tool which has steel cutting edges, carbide is more economical because it lasts much longer.

Q: What is the difference between HSS and carbide end mills?

A: Carbide end mills typically provide better rigidity than HSS end mills, and can be operated 2-3x faster. This is primarily due to the material properties of carbide allowing it to have a substantially higher heat tolerance. Carbide is not the best option in all circumstances, however. For machines with lower horse-power and lower rigidity, running carbide end mills at a sub-optimal RPM can reduce their overall effectiveness and tool life.

Q: What is the most commonly used end mill?

A: End mills are made of a few different materials, but “high-speed steel” (HSS) and tungsten carbide are two of the most common. The HSS tools are more forgiving than carbide, as carbide is brittle and can chatter and shatter. HSS is also cheaper than carbide, but it tends to dull faster than carbide.

Q: What are carbide end mills made of?

A: Cemented Carbide—the most popular substrate used in milling cutters/end mills, it is an alloy of Tungsten carbide (WC) mixed with cobalt (Co) to make a powder which is then pressed and sintered. The hardness of cemented carbide is at a level between diamond and sapphire and weight is about twice as iron.

Q: How do you cut off carbide end mills?

A: Cutting the end off a carbide end mill so that the end can be replaced in good material. We're using the Tradesman DC Variable Speed Grinder. This machine is configured to put set screw flats on carbide end mills on the left hand side and cut off carbide end mills on the right hand side.

Q: What is the best material for end mills?

A: Two of the most common materials used in the manufacturing of end mills are high speed steel (HSS) and carbide. HSS is useful in older, slower, or less rigid machines as well as one off or very short run production. It will run slower, but is less expensive, less brittle and more forgiving of unstable conditions.

Q: What are the disadvantages of carbide?

A: Low Toughness. If you want something with high toughness, carbide isn't likely to be your go-to material. Toughness expresses the ability to sustain shocks, suddenly applied and relieved loads, or major impacts, without breaking. Often, materials with high wear resistance have low toughness.

Q: Can you sharpen carbide end mills?

A: Sharpening your carbide end mills & carbide drills is a complex task. The process involves regrinding the end mill's / drill's cutting edges as well as sharpening the points and flutes. However, it is important to note that this should be done by a professional and not done at home.

Q: How hard is a carbide end mill?

A: The carbide end mill is also known as a carbide end mill with cement. The hardness of the tool is typically between 88 and 96 HRA degrees. With a surface coating, though, the difference becomes apparent. The most affordable approach to increasing an end mill's performance is applying the proper layer.

Q: What is the difference between end mill and shell end mill?

A: A shell end mill is a type of cutting tool that is primarily used in industrial milling applications. It differs from a drift drill in terms of geometry, application and manufacture. While a drill mill can only cut in the axial direction, an end mill, on the other hand, can cut in virtually all directions.

Q: What are the 3 common types of endmills?

A: Roughing Endmills. Roughing Endmills also known as hog mills, are used to remove a large amount of material in a single pass.
Rounding Endmills. Corner Rounding Endmills are used to mill round edges.
Undercutting Endmills. Undercutting Endmills are also known as lollipop cutters.

Q: What is the cutting depth of a carbide end mill?

A: In general, a good rule of thumb is to use a cutting depth that is no more than 1-1.5 times the diameter of the end mill. For example, if you are using a 1/4-inch end mill, the recommended cutting depth would be between 0.25 and 0.375 inches.

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