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Chamfer end mills are commonly used for a variety of tasks, such as breaking edges, deburring, and creating chamfers on holes or slots where a countersink is desired. When selecting one for use in CNC machining, there are several factors to consider.
The material of the object being worked upon should be taken into account when choosing an end mill. Different materials require different cutting tool geometries and coatings for optimal performance. The angle of the chamfer cam also be selected, either at 45 degrees, 60 degrees, or a custom angle. This angle determines both the width and depth of the chamfer's edge. The diameter of the end mill must be considered as well. While smaller diameters are better for more intricate chamfers, larger diameters are better for more visible countersinks. Additionally, the flute count of the tool can affect chip evacuation and surface finish, so higher flute counts can have more positive results in certain applications. Finally, certain coatings, such as TiN (Titanium Nitride) or TiAlN (Titanium Aluminum Nitride) can improve the tool's durability and chip evacuation.
Carbide chamfer end mills have several features that make them well-suited for machining applications. Here are some notable features of carbide chamfer end mills:
Carbide chamfer end mills are typically made from solid carbide, which is a composite material consisting of tungsten carbide particles bonded together with a cobalt or nickel binder. Carbide is known for its exceptional hardness, wear resistance, and heat resistance, making it suitable for demanding machining operations.
Carbide chamfer end mills offer high hardness, allowing them to maintain their cutting edge sharpness for extended periods. This hardness enables them to withstand the high cutting forces encountered during machining and resist wear, resulting in longer tool life compared to other materials.
Carbide has excellent heat resistance, enabling carbide chamfer end mills to withstand high cutting temperatures without significant deformation or loss of hardness. This heat resistance is particularly important when machining materials that generate high heat, such as stainless steel or titanium.
Carbide chamfer end mills can be manufactured with various cutting edge geometries, including single-flute, two-flute, or multiple-flute designs. The specific geometry impacts factors such as chip evacuation, cutting stability, and surface finish. Manufacturers offer a range of options to suit different machining requirements.
Carbide chamfer end mills may be available with various coatings to further enhance their performance. Common coatings include TiN (Titanium Nitride), TiAlN (Titanium Aluminum Nitride), and AlTiN (Aluminum Titanium Nitride). These coatings can provide additional benefits such as increased hardness, improved lubricity, reduced friction, and enhanced chip evacuation.
Carbide chamfer end mills are manufactured with high precision and tight tolerances, ensuring consistent performance and accurate results. This precision is crucial for achieving precise chamfers and maintaining dimensional accuracy in the machined workpiece.
Overall, carbide chamfer end mills offer excellent hardness, wear resistance, heat resistance, and precision, making them a reliable choice for a wide range of machining applications. Their durability and performance make them well-suited for demanding materials and machining operations, improving productivity and reducing tooling costs in the long run.
When using chamfer end mills, several important cutting parameters should be considered to achieve optimal results. Here are some key parameters to keep in mind:
Feed Rate: The feed rate refers to the speed at which the cutting tool advances into the workpiece. It is typically measured in distance per revolution (inches per minute or millimeters per minute). A proper feed rate ensures efficient material removal and helps prevent tool wear. Adjust the feed rate based on the material being machined, the tool diameter, and the machine's capabilities.
Cutting Speed: The cutting speed is the relative surface speed between the cutting tool and the workpiece. It is typically measured in surface feet per minute (SFPM) or meters per minute (m/min). The cutting speed is influenced by the material being machined and the tool material. Consult cutting speed recommendations provided by the tool manufacturer or refer to machining handbooks for appropriate cutting speed ranges.
Depth of Cut: The depth of cut is the distance between the original surface of the workpiece and the final machined surface. It determines how much material is removed during each pass. It's important to consider the tool's diameter and the desired chamfer width when determining the appropriate depth of cut. Avoid excessive depths of cut that can overload the tool or machine, leading to poor surface finish or tool breakage.
Stepover: The stepover, also known as radial depth of cut or scallop height, is the distance between each pass of the tool. It determines the width of the tool path and affects the surface finish. A smaller stepover provides a finer finish but may require more passes, while a larger stepover can remove material more quickly but may result in a rougher surface. Experiment with different stepover values to find the optimal balance between productivity and finish quality.
Coolant/Lubrication: Depending on the material being machined, using coolant or lubrication can help dissipate heat, reduce friction and chip welding, and prolong tool life. Some materials, like aluminum, benefit from the use of coolant to prevent chip buildup and improve surface finish. Refer to the manufacturer's recommendations or machining guidelines for specific coolant/lubrication requirements.
Tool Path Strategy: The choice of tool path strategy can also impact the performance of chamfer end mills. Common strategies include conventional milling (climb milling), where the tool rotates against the feed direction, and climb milling, where the tool rotates in the same direction as the feed. Each strategy has its advantages and considerations, such as tool deflection, surface finish, and chip evacuation. Choose the strategy that best fits your application.
Chamfer end mills are commonly used for machining a wide variety of materials, including metals, plastics, wood, composites, and ceramics.
Metals such as aluminum, steel, stainless steel, brass, and copper are all suitable for machining with chamfer end mills. They can be used for creating chamfers on edges, countersinking holes, and removing burrs.
When it comes to plastics like acrylic, polycarbonate, nylon, and ABS, chamfer end mills can provide a nice clean chamfered edge without causing melting or chipping.
Woodworking applications also benefit from chamfer end mills, as they can be used to create chamfers or beveled edges on wooden workpieces, both softwoods and hardwoods.
Composites such as fiberglass-reinforced plastics (FRP) and carbon fiber composites also require special cutting tools for machining. In this case, chamfer end mills with diamond or ceramic coatings must be employed to avoid delamination and achieve precise chamfers.
In certain specialized applications, chamfer end mills are even used for machining ceramics. For these hard and brittle materials, diamond or ceramic coatings are recommended on the chamfer end mills.
The selection of the most suitable chamfer end mill and cutting parameters is dependent on the type of material to be machined. Characteristics of the material such as hardness, brittleness, and thermal conductivity all play a role in deciding the right tool for optimal machining performance and tool life.
SUPAL Chamfer End Mills offer a complete solution for chamfering with indexable chamfer mill. Our Chamfer End Mills are available for sale with cutting width of 0.5-2.0mm and shank diameter of 3-6mm. The materials used are carbide for maximum performance and strength during chamfering applications.
We provide technical support and service for Chamfer End Mill.
If you face any problem in setup and operation of our Chamfer End Mill product, our technical support team is here to help. We provide solutions to different types of technical issues with our product. Our technical support staff have the technical knowledge and experience to help you diagnose and repair any problems you might have with our products.
We also provide maintenance and repair services for our Chamfer End Mill products. Our experts can inspect, diagnose and repair any mechanical or electrical issues that may arise in the usage of our products. We can also provide spare parts for our products, as well as installation and setup services.
If you have any questions or need assistance with our Chamfer End Mill products, please do not hesitate to contact our technical support team.
Chamfer End Mill
Packaging and Shipping
The Chamfer End Mill is packed in a strong, corrugated cardboard box and sealed with quality packing tape to ensure safe and secure delivery. The package contains all the necessary pieces and instructions to install and use the product. The package also includes a product warranty.
The package is shipped via USPS or FedEx, depending on the customer’s shipping preference. Delivery typically takes 2-3 business days. The cost of shipping will depend on the weight and size of the package.
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