3 Flutes Roughing End Mill

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.

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Product Introduction

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.

2 Flutes Flat Micro-diameter Milling Cutter

This milling cutter is made of high-quality carbide material, which has excellent wear resistance and rigidity. This means it delivers reliable, precise cutting results and increases tool life.

2F Taper Ball Nose Endmill with Coating

Made of hard alloy material, this end mill has extremely high wear resistance and cutting accuracy, and it can also ensure that it is not easy to deform or crack during high-speed machining.

2F Taper Ball Nose Milling Cutter without Coating

This 2F taper ball nose milling cutter without coating has high hardness and high strength, which can quickly cut various materials and improve processing efficiency.

One Spiral Flute Bits

One of the outstanding features of this drill bit is its spiral flute design. This design provides a unique twist on conventional drills, significantly improving their performance.

2 Flutes Flat Bits

2 flutes flat bits can be widely used in many different fields. Especially in the field of woodworking, this drill bit can be used for drilling flat or wall-mounted wood and boards, etc.

2 Flutes Ball Nose Bits

The hardness of this 2 flutes ball nose bits can reach 60HRC and has a high service life, so it is not easy to be damaged and can reduce the frequency of replacing the drill.

2 Flutes Ball Nose Long Neck End Mill

This 2 flutes ball nose long neck end mill is versatile enough to handle a wide range of applications, including all materials from aluminum to stainless steel to plastic and more.

3 Flutes Roughing End Mill

Its high-precision cutting ability and high cutting efficiency can greatly improve processing efficiency and product quality, forming higher production efficiency and added value.

3 Flutes Roughing Milling Cutter

Its helical design ensures it can achieve high cutting speeds without excessive heat generation, while the sharp and durable cutting edges ensure it can handle the toughest jobs with ease.

What is Roughing End Mill?

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. Roughing end mills quickly remove large amounts of material.

This kind of end mill utilizes a wavy tooth form cut on the periphery. These wavy teeth act as many successive cutting edges producing many small chips. This results in a relatively rough surface finish, but the swarf takes the form of short thin sections and is more manageable than a thicker more ribbon-like section, resulting in smaller chips that are easier to clear. During cutting, multiple teeth are in simultaneous contact with the workpiece, reducing chatter and vibration.

Advantages of Roughing End Mill

Roughing End Mills have the ability to achieve quick feed, and subsequent finishing operations may remedy any errors that may have been made, which helps to assure product quality.
When the processing phases are divided, the benefits of using rough and final end mill equipment may be exploited to their maximum potential. Roughing End Mills are characterised by having high power, high efficiency, and strong stiffness, whereas finishing equipment is characterised by having high precision and minimal error.
Roughing end mill has the ability to discover a variety of flaws in the blanks, such as sand holes, air holes, inadequate machining allowance, etc., which makes it convenient for quick repair or scrapping, so that processing time and expense are not wasted.
The workpiece has a significant amount of residual stress after it has been subjected to hot working. Aging the workpiece may be arranged to remove the residual stress, and final machining can be set to remove the deformation that has occurred after the workpiece has cooled.
Before the mechanical finishing, the roughing end mill is used to prepare the surface. Finishing can preserve the surface from wear caused by the subsequent steps.

Available Coating of Roughing End Mills

Titanium Aluminum Nitride (TiAlN) is an outstanding coating that provides excellent wear resistance, especially in high-temperature applications. It is good for hard materials like pre-hardened alloy steels up to HRc45.

Aluminum Chromium Nitride (AlCrN) has remarkable wear resistance at lower speeds and feeds, as well as tremendous heat resistance at high speed. It is the coating of choice for titanium and high-temperature alloys.

Titanium Carbon Nitride (TiCN) provides excellent abrasive resistance, and hardness to the cutting edge. It does not perform well at very high temperatures, so properly applied coolant is a must. This coating is perfect for aluminum and abrasive high-silicon aluminum alloys.

The Anatomy and Functionalities of Roughing End Mills

Serrated or Wavy Cutting Edges

The hallmark feature of a roughing end mill is its serrated or wavy cutting edges. By breaking up the chips into smaller segments, these serrations ensure efficient chip evacuation, preventing tool clogging.

Flute Geometry

Flutes are the grooves or channels carved into the body of the end mill. Roughing end mills typically have a more profound and more pronounced flute geometry. These deeper flutes are designed to accommodate and evacuate larger volumes of chips, a byproduct of its aggressive material removal strategy.

Core Strength and Helix Angle

The core of the roughing end mill is robust, built to endure the rigorous demands of its tasks. This strength is enhanced by the helix angle of its flutes. While a higher helix angle (around 45 degrees) offers better surface finish and is suitable for softer materials, roughing end mills usually come with a low helix angle.

Coating Enhancements

For roughing end mills, these coatings not only extend tool life but also help in reducing friction.

End Geometry and Chip Breakers

A flat end allows for efficient plunging and pocketing. Meanwhile, chip breakers, which are essentially indentations on the mill's surface, further facilitate the breakdown of chips, ensuring they don't interfere with the milling process or damage the workpiece.

Shank and Tool Holders

The shank is the non-cutting part of the end mill, which is held by the machine's tool holder.

Roughing End Mill vs. Finishing End Mill

Roughing End Mill

Pros:

Fast feeding can be realized to complete machining quickly and efficiently.
The material removal rate is high.
Any defects can be identified and either repaired or scrapped quickly.
The design reduces vibrations for quieter operation and an efficient cut.
A higher depth of cut can be achieved.
Can use cutters with less sharp edges that take a high chip load.

Cons:

A rough finish is left, requiring a finishing pass to make improvements.
Less accuracy and tolerance are possible compared to finishing end mills.

Finishing End Mil

Pros:

Improved surface finish.
A low feed rate can make it a good choice for beginners.
Higher dimensional accuracy compared to roughing end mills.
Can provide close tolerance levels.
A low amount of material removed.

Cons:

Lower feed rates and cutting depths aren't suitable for all applications.
Sharp cutters that take a low chip load are required.
Finishing can only be carried out after roughing has been completed.

Common Milling Problems and Solutions

Excessive Chatter: Vibration and sound are excessive when the tool engages the workpiece.

Possible Solutions:

Increase your feed
Reduce your cutting forces by reducing speed and/or feed or axial and/or radial depth of cut
Increase your system's rigidity by changing over to a stub length end mill or improving your workpiece fixturing
Change geometry - use an end mill with variable flute spacing or a small circular margin
Poor surface finish

Surface Finish: Work surface looks uneven and feels rough.

Possible Solutions:

Increase system rigidity
Increase speed
Reduce feed
Change to higher helix geometry
Change to an end mill with more flutes
Excessive Wear of End Mill

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: Are roughing end mills worth it?

A: Roughing end mills have a higher feed rate, which means that you can work quickly with them. The lower feed rate and cutting depths of finishing end mills help to make them the better choice for their purpose. Due to its high feed rate and depth of cut, a roughing end mill will result in more visible feed marks. This leaves a rougher surface, which isn't necessarily suitable for the desired end product.

Q: What is the main difference between a roughing endmill and finishing endmill?

A: Roughing End Mills: Higher cutting speeds and feed rates are common with roughing end mills to remove material quickly. Finishing End Mills: Lower cutting speeds and feed rates are used to achieve better precision and surface finish.

Q: What is the difference between fine and coarse roughing end mill?

A: Haas roughing end mills come in fine- and coarse-pitch versions. Fine-pitch scallops are smaller and better for lighter cuts in hard materials. The fine-pitch end mills leave a better finish, and don't require as much stock to be left to clean up with a finish pass using standard end mill.

Q: What are the most common three basic end mill types?

A:Square Endmills. Square Endmills have a 90-degree profile. They are used for all-around milling.

Weldon Endmills. Weldon Shank Endmills are produced with a Weldon flat to prevent any slippage.

Ball Endmills. Ball Endmills (Ball Nose) have a round cutting surface used to mill contoured surfaces.

Q: What are the different types of roughing end mills?

A: Carbide, Cobalt and HSS. They are mainly used to rough mill the material off when large amounts of material are removed. They come in carbide, cobalt, and HSS substrates, and are often PVD coated with AlTiN or ZrN. They come in fine, medium and coarse pitch scallops.

Q: How do I choose an end mill?

A: Consider factors such as material, cutting diameter, flute count, coatings, and cutting speed and feed rate when selecting an end mill. By taking the time to choose the right end mill for the job, you can ensure efficient cutting and a high-quality finish.

Q: What are the most used end mills?

A: Square end mills are the most common ones and can be used for many milling applications, including slotting, profiling and plunge cutting. Corner-radius end mills have slightly rounded corners that help distribute cutting forces evenly to prevent damage to the end mill and extend its life.

Q: What is the rule for cutting end mills?

A: An end mill can only remove a certain amount of material at once. The maximum depth and width of cut is 1/2 of the end mill diameter. For example, a 1/2" end mill can cut no more than 1/4" deep and 1/4" wide in a single pass. A slotting cut is an exception to the width of cut rule.

Q: What size are roughing end mills?

A: Great for large surface area work, will shape and form metal components. Suitable for use on steel, alloy steel, tool steel, cast iron and ferrous metals. For use in a CNC machine, lathe or milling machine. Available sizes: 6mm, 8mm, 10mm, 12mm, 14mm, 16mm.

Q: Why down milling is better than up milling?

A: The evaluations of the results are focusing on the comparison of up-milling and down-milling operations using physical vapor deposition (PVD) - coated carbide inserts. Machining parameters; depth of cut, feed rate and cutting speed are considered during the evaluation. The experimental results showed that down-milling operation has better results in terms of tool wear than up-milling operation. Chipping on cutting tool edge was the primary reason that responsible to notch wear with prolong machining.

Q: What are the serrations on a roughing end mill designed for?

A: Serrated end mills offer reduced milling forces, increased chatter stability and superior chip breaking ability once they are designed and employed properly. Although serrated end mills are often used in industry, the literature on these tools is quite limited compared to standard milling tools.

Q: How do you calculate end mill cutting speed?

A: Speed (RPM) = (SFM x 3.82) / D.
Feed (IPM) = RPM x FPT x Z.
SFM (Surface Feet per Minute) = (RPM x D) / 3.82.
IPT (Inches per Tooth) = (IPM / RPM) / Z.
MRR (Cubic Inches per Minute) = IPM * WOC * DOC.
AFPT (@ less than 1/2 dia. WOC) = IPM x sqroot of (D / WOC)
HP (Horsepower Consumption) = MRR x mf.

Q: What kind of end mill for stainless steel?

A: For traditional roughing, a 4 or 5 flute end mill is recommended. 5 flute end mills will allow for higher feed rates than their 4 flute counterparts, but either style would work well for roughing applications. Below is an excellent example of traditional roughing in 17-4 Stainless Steel.

Q: What is the difference between roughing tool and finishing tool?

A: Roughing: Roughing generally uses larger cutting tools capable of withstanding the rigors of aggressive, heavy cuts. Finishing: Finishing employs smaller, finer cutting tools that take lighter cuts to achieve a smooth surface and precise dimensions.

Q: What angle do you cut an end mill?

A: Helix angles generally come as low as 12°to as high as 60°. Most general purpose end mills use between a 25°and 30°angle where basic sharpness and cutting edge strength is maintained. Increasing the helix angle improves stock removal and is useful in machining at increased speeds and feeds. A higher helix angle also reduces tool deflection and transfers stress vertically through the spindle, as opposed to horizontally.

Q: What is the angle of an end mill cutter?

A: The helix angle of a tool is measured by the angle formed between the centerline of the tool and a straight line tangent along the cutting edge. A higher helix angle used for finishing (45°, for example) wraps around the tool faster and makes for a more aggressive cut. A lower helix angle (35°) wraps slower and would have a stronger cutting edge, optimized for the toughest roughing applications.

Q: Can an end mill cut vertically?

A: Drill bits plunge vertically into material to create holes while end mills typically cut horizontally and laterally, but most mills can actually cut vertically as well. End mills are designed with purpose and each tip shape offers a unique clearing path for various applications.

Q: What is the use of roughing end mill?

A: Roughing end mills are used to quickly remove large amounts of material. They work by having serrations (very fine teeth) on the flutes. Because of the serrations, they leave a lot of tooling marks on the walls of the cut, so a separate finishing pass with a conventional solid end mill must be made.

Q: What are the benefits of roughing end mills?

A: Roughing end mills have cutting edges that are serrated for improved performance. During the machining process, this results in chips with a finer grain and decreases vibration. They provide the work item a surface finish that is more rough than smooth.

Q: What are two common materials used to make end mills?

A: A wide variety of materials are used to produce the cutting tools. Carbide inserts are the most common because they are good for high production milling. High speed steel is commonly used when a special tool shape is needed, not usually used for high production processes.

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3 Flutes Roughing End Mill