The components of an end mill play a crucial role in determining its performance and suitability for machining different materials. The best way to understand the importance of different features of an end mill is start with the material you are cutting.  Just like a butter knife is not good for cutting steak, selecting features for an end mill is very dependent upon the material you're cutting.

Let's start with some background information.  The ISO 513 is a standard that classifies materials based on their machinability and provides guidelines for cutting speeds, feeds, and tool selection. ISO 513 provides a classification system for the machinability of materials, organizing them into categories based on the characteristics which influence their behavior during machining processes. The main categories include:

• ISO P for steels
• ISO M for stainless steels and super alloys
• ISO K for cast iron
• ISO N for non-ferrous metals
• ISO S for heat-resistant super alloys
• ISO H for hardened materials.

Each category is tailored with specific recommendations for cutting speeds and feeds to optimize machining efficiency, tool life, and surface quality. This standard serves as a guideline for manufacturers and machinists to select the most suitable cutting tools and parameters for machining different material types, thereby enhancing productivity and reducing costs.

Now, let's dig into the details. Below you'll find the key components of an end mill and how they relate to machining different ISO 513 material types:

1. Core Diameter: The core diameter of an end mill refers to the diameter of the solid, central part of the tool. It affects the tool's strength and rigidity. When machining harder materials (e.g., ISO P and ISO K materials), it's often advisable to use end mills with a larger core diameter to ensure stability and reduce the risk of tool deflection or breakage. For softer materials (e.g., ISO M and ISO N materials), a smaller core diameter may suffice.
2. Helix Angle: The helix angle is the angle formed by the flute helix and a line parallel to the end mill's axis. It affects chip evacuation, tool rigidity, and cutting forces. A higher helix angle (e.g., 45 degrees) is often suitable for softer materials as it helps with chip evacuation and reduces cutting forces. In contrast, a lower helix angle (e.g., 30 degrees) provides better tool rigidity and may be preferable for harder materials.
3. Edge Preparation (Edge Prep) Types: Edge preparation refers to the treatment of the cutting edges of the end mill to improve tool life, performance, and surface finish. The choice of edge prep type can vary depending on the material being machined:
   • Uncoated: Suitable for general-purpose use on a wide range of materials.
   • TiN (Titanium Nitride) Coating: Provides good wear resistance and can be used for ISO M and ISO N materials.
   • TiCN (Titanium Carbonitride) Coating: Offers better wear resistance than TiN and is suitable for a wider range of materials, including ISO P and ISO K materials.
   • TiAlN (Titanium Aluminum Nitride) Coating: Provides high-temperature stability and is effective for machining ISO S and ISO H materials, as well as stainless steels.
4. Number of Flutes: The number of flutes on an end mill affects chip evacuation, surface finish, and cutting speed. The choice of the number of flutes can vary with material type:
   • 2 Flutes: Typically used for softer materials to aid in chip evacuation and reduce cutting forces.
   • 3 Flutes: A versatile option suitable for a wide range of materials.
   • 4 Flutes or More: Provide more cutting edges and are often used for harder materials where higher feed rates can be achieved while maintaining surface finish.

When selecting an end mill for a specific ISO 513 material type, it's important to consider factors like material hardness, workpiece geometry, cutting parameters (e.g., cutting speed and feed rate), and desired surface finish. Additionally, referring to machining guidelines and consulting with tool manufacturers can help you make informed decisions about the components of the end mill and their suitability for the machining task at hand.
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The anatomy of an end mill refers to its various components and features, each of which plays a critical role in its cutting performance. End mills are rotary cutting tools used in milling operations to remove material from a workpiece.

​Here's a breakdown of the key parts of an end mill:

1. Shank: The shank is the cylindrical portion of the end mill that is designed to be held in the tool holder of a milling machine. It provides a means for securing the end mill in the machine spindle. Shank diameters can vary and must match the tool holder.
2. Flutes: Flutes are the helical or spiral-shaped grooves that run along the length of the end mill. They are the primary cutting edges of the tool. The number of flutes can vary; common options include two, three, four, or more flutes. The choice of the number of flutes depends on factors like material type, desired surface finish, and machining conditions.
3. Cutting Edge: The cutting edge is the sharpened portion of each flute where material removal occurs. It's where the actual cutting action takes place. The quality of the cutting edge, including its sharpness and geometry, greatly influences cutting performance.
4. Flute Length: The flute length is the portion of the end mill's length that includes the flutes. It determines how deeply the end mill can cut into the workpiece in a single pass. Longer flute lengths are suitable for deeper cuts, while shorter flute lengths are typically used for shallower cuts.
5. Overall Length: The overall length of the end mill includes the shank and flute length. It's important to consider the overall length when choosing a tool to ensure it can reach the required depth within the workpiece without interference.
6. Helix Angle: The helix angle is the angle formed by the helical flutes and a line parallel to the end mill's axis. It influences chip evacuation, cutting forces, and tool rigidity. The choice of helix angle can vary depending on the material being machined and the desired cutting characteristics.
7. Corner Radius: Some end mills have a corner radius instead of a sharp corner at the bottom of the cutting edge. This radius can improve tool life, reduce stress concentrations, and enhance surface finish, especially in contouring and profiling operations.
8. Coatings: Many modern end mills feature coatings or surface treatments to improve wear resistance and tool life. Common coatings include TiN (Titanium Nitride), TiCN (Titanium Carbonitride), and TiAlN (Titanium Aluminum Nitride), among others. The choice of coating depends on the material being machined.
9. Flute Design: The design of the flute can vary, and it may include features like variable flute geometry, chip breakers, or special profiles to optimize chip evacuation and performance for specific applications.
10. Tool Diameter: The tool diameter refers to the maximum width of the end mill and determines the size of the cut it can make. End mills are available in various diameters, and the selection depends on the machining requirements.

At Browne & Co, we are thrilled to introduce the latest addition to our cutting-edge tool lineup – the Fullerton Tool 3125 V-MAC End Mill. Engineered to perfection, this high-performance end mill has proven its mettle in milling aerospace high-temp alloys, stainless steels, and inconels, offering unsurpassed performance that sets it apart in the machining industry.
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​The 3125 V-MAC high-performance end mill is your solution for tackling high cutting forces with ease. Designed for precision milling in aerospace materials inclduing  high-temp alloys, stainless steels, and inconels, this tool delivers ultimate part finishes and reliable performance.

5 things you should remember about the new 2135 V-Mac!
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1. Enhanced Flute Design for Optimal Chip Control: The V-MAC's advanced flute design goes beyond conventional end mills, providing superior chip control. This not only improves the overall machining process but also reduces cutting forces, allowing for aggressive speeds and feeds without compromising on precision.
2. Staggered Flute Geometry for Vibration Control: Vibrations can be a significant concern in high-speed machining. The V-MAC's staggered flute geometry is specifically engineered to limit vibrations, ensuring stability and consistency in performance even in demanding applications.
3. Engineered Core for Robust Axial Strength: Achieving optimal tool stability is crucial in high-performance machining. The V-MAC is crafted with an engineered core that provides robust axial strength, enhancing its durability and reliability in the face of challenging machining conditions.
4. FC-21 Coating for Extended Tool Life: The FC-21 coating on the V-MAC resists fatigue and micro-chipping, resulting in a consistent cutting edge over an extended tool life. This coating ensures that the end mill maintains its peak performance even in prolonged and rigorous machining operations.
5. Versatility in Design: The 3125 V-MAC is a versatile solution, available in both square end and corner radius configurations. Whether you need a Stub or Standard length, this end mill caters to your specific machining requirements. 

The basic mechanics of forming a chip are the same regardless of the base material. As the cutting tool engages the workpiece, the material directly ahead of the tool is sheared and deformed under tremendous pressure. The deformed material then seeks to relieve its stressed condition by fracturing and flowing into the space above the tool in the form of a chip. 

The important difference is how the chip typically forms in various materials.
 
Regardless of the tool being used or the metal being cut, the chip forming process occurs by a mechanism called plastic deformation. This deformation can be visualized as shearing. That is when a metal is subjected to a load exceeding its elastic limit.

​The crystals of the metal elongate through an action of slipping or shearing, which takes place within the crystals and between adjacent crystals.

Cast Iron, Hard Brass and other materials that produce a Powdery chip.
 
“Discontinuous Chip - Discontinuous or segmented chips are produced when brittle metal such as cast iron and hard bronze are cut or when some ductile metals are cut under poor cutting conditions.

Medium to High carbon and alloy Steels – Long Chipping Materials
 
“Continuous Chip - Continuous chips are a continuous ribbon produced when the flow of metal next to the tool face is not greatly restricted by a built-up edge or friction at the chip tool interface. The continuous ribbon chip is considered ideal for efficient cutting action because it results in better finishes. Unlike the Type 1 chip, fractures or ruptures do not occur here, because of the ductile nature of the metal.”

Low carbon Steels, Stainless Steels, Nickel Alloys, Titanium, Copper, Aluminum and other soft, “gummy’ Materials.
 
Sheared Chips or as some refer to it “Continuous Chip with a Built-up Edge (BUE). The metal ahead of the cutting tool is compressed and forms a chip which begins to flow along the chip-tool interface.

These metals readily deform in front of the cutting edge and have to be "sheared" by the tool. What the above paragraph doesn’t tell you is that these materials require tools with sharper cutting edges than those used for machining cast Iron or higher carbon content Steels. The chips tend to compress onto the face of the tool which can result in built-up edge. 

The chips formed when cutting these metals are thicker than those produced by Medium Carbon or Alloy Steels at the same Feed Rates and Depths of Cut. These thicker chips are stronger and harder to break. Destiny Tool, through a combination of rake face geometry, carbide substrate and concentricity tolerance is able to enable the chip to more readily "separate from itself" which not only improves MRR, but also reduced heat into the end mill and thereby extends tool life as the feed rate increases.

​High strength metals such as Stainless Steel, Nickel Alloys and Titanium generate high heat and high cutting pressures in the area of the cutting edge. This results in reduced tool life compared to easier to machine materials. 

• This article was originally written in 2001
• Portions of this have been edited from http://www.manufacturingcenter.com/tooling/archives/0101/0101bk.asp
• Plastic Deformation image by Jutka Czirok, Design Technology and ICT Teacher
• Special thanks to Charles Colerich, who created these drawings for me in 1994.

Dapra Corporation has announced the DAPRA Next Technology - High Feed Indexable Milling Platform - "VAPOR™ powered by TRI-X2".

VAPOR™ is ideal for extreme machining. The VAPOR™ platform has unique elements in body design and TRI-X2 insert geometry for higher metal removal rates and extended tool life. 
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The design is created for lighter, faster cutting and versatility through positive cutting geometry and excellent ramping capability. It's designed with a new double-sided insert series for lower cost per usable cutting edge. Inserts are installed with a large insert screw for longevity and easy indexing. This makes the advanced design highly shock resistant through-hardened steel.

• Available in both endmill and shell mill configurations
• A diameter range of 0.500” - 2.00”, with up to 7 flutes
• Through coolant holes for maximum control and chip evacuation
• Initial offering is a double-sided 6mm insert series
• Additional product series coming soon!

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by Bernard Martin

As a result of titanium's material properties it's making it become evermore popular in the aerospace, defense, shipbuilding, medical adn dental industries. It's also what makes it considered a "more difficult to machine" material.  Let's dig into that a bit more. 

Generally, titanium grades 1 through 4 are considered commercially pure titanium with varying requirements on ultimate tensile strength while Grade 5 is what is most often seen in the machining industry. It's often alloyed with 6% aluminum and 4% vanadium.  This is what is commonly known as 6Al4V or Ti 6-4. Also quite common is 4Al4V or Ti 4-4.

Why difficult?  Well, first it has low Young’s modulus meaning that is more elastic than other materails: It's "gummy" which often causes spring back and chatter during machining and can readily generate long stringy chips if you don't have the correct edge prep. On top that,  it's also prone to work hardening and galling super easily. You've got to keep the cutter in-the-cut: Insert cutters just aren't as good as solid endmills at doing this.  

Next, titanium does not have good thermal conduction properties like aluminum.  Instead of heat being evacuated in the chips or transferred to the base material, heat tends to be transferred to the cutting tool which reduces it's tool life. Heat kills. Tool life declines. The right coating helps. 

The final icing on the cake is that titanium is prone to work hardening. During uniaxial loading, the initial rate of hardening is higher in compression so if you come back for another pass you need to get under the work hardened layer, that is, leave enough material for a finish pass to get under the layer or your tool life will suffer and your part finishes will decline with it. Ideally, finish to size in the final pass if you can. 

The trick to machining titanium has always been to keep consistent coolant flow to evacuate the chips and maintain a consistent chip load.  Again, rough to your finish size.  Don't let it work harden.  

That's what we've learned about titanium over the past couple of decades.  There has been a ton of research on titanium's properties and that research has led to further refinement of the cutting tool geometry at Fullerton. 

The design of Fullerton's 3116 TiMill is based upon over a decade of aerospace testing and development and addresses many of the machining issues that Titanium presents.  It's a 6-flute tool built with a 38°helix.  The increased number of flutes allows for the tools to remain "in the cut" longer and more consistently. It doesn't induce as much heat as a lower number of flutes tends to do.  instead, it's consistent.  The 38°helix evacuates the chip at a more optimum angle than a 35°, 37.5° or 40° helix that predecessors made by competitors have tried.

CHARDON, OH - Browne & Co is excited to announce that they begin representation of Dapra Corporation products in December 2022.  

Dapra specializes in the design, service, and support of American-made, high-performance indexable carbide milling tools for a broad range of operations.

Dapra Corporation is a U.S.-based, multi-generation family-owned parent company to multiple brands which provides high-quality engineered solutions for various manufacturing and industrial markets. From indexable cutting tools to permanent part marking equipment Dapra Corporation continues to develop and invest in solutions to empower the success of manufacturers across North America.

For over 65 years Dapra has provided milling, workholding, and power tool solutions to a wide array of manufacturing segments including aerospace, automotive, mold and die, and firearm. With their proven high-performance solutions combined with industry-leading application expertise and a robust distribution network Dapra has earned the trust of businesses from around the world.

From small workshops to globally diversified manufacturers, they are more than a supplier, they are a partner in yours and our success.

According to David Browne at Browne & Co., "At our core we have always had a very strong presence in CNC milling products.  We're at the spindle.  Dapra really matches what our company does and we're excited to launch into 2023 with Dapra's high performance milling products."

Browne & Co. is excited to work with our customers with these premiere products that include:

• VAPOR™ High Feed Mill - a high feed indexable mill that maximizes metal removal rates. Utilizing light depth of cut (DOC) combined with extreme feed per tooth (FPT) to increase productivity
• ​​Copy / Face Milling - This family of end mills and face mills (shell mills) provides aggressive material removal so you can maximize your copy milling operations with our single- and double-sided Toroid series button cutters.
• Shoulder & Edge Milling - Obtain extreme metal removal with our single-sided and EDGE² DSS double-sided 90° Square Shoulder milling tools. These high-performance end mills and face mills (shell mills) cut to a true 90 degrees, generating smoother finishes
• ​Finishing / 3D Contour Milling - Achieve superior surface finishes with our single-sidedand EDGE² SBN double-sided Ball Nose series. Use ball nose tools for fine finishing of slopes and curves. Back draft/bull nose tools are great for finishing tapered walls and deep straight walls.

Guest Blog by Mark Donze at Fullerton Tool 

First, let's discuss general purpose end mills. General Purpose (GP) End Mills are standard single, 2, 3, or 4 flute geometry end mills made for use in a wide variety of materials.

​Benefits of General Purpose End Mills:

• Lower prices
• Very versatile - they work in a variety of materials and applications
• Typically easier to resharpen - general-purpose end mills can usually be resharpened by the user or by a local regrind shop, whereas a high-performance end mill typically will need to be sent back to the OEM for resharpening

Next, High-Performance (HP) End Mills contain specialized geometries for a specific material being cut.

Benefits of High-Performance End Mills:

• Material and/or application-specific - This does not mean that an HP cutter will not work in more than the listed materials or applications. For example, our Fury end mill is recommended for a wide range of materials and applications and will cut almost anything and any tool path. So don't be afraid to experiment.
• Better tool life, especially in difficult-to-machine Materials - HP cutters typically require less frequent tool changes and fewer offsets.
• More adapted to high-speed machining or other advanced milling techniques.
• Better surface finishes on your parts.
• Usually have premium coatings that target a specific range of materials.
• Typically have edge preps like hones or polishes that target a specific range of materials

With this information in mind, if you are a company that does small runs in a wide variety of materials you may prefer GP end mills. Whereas, if you are making high-volume parts where cycle-time and up-time are king, you may prefer an HP end mill for your use. Remember, there are no hard lines drawn. Each application is different and preference is ultimately up to you, the end-user. 

If you aren't sure, you can contact your Fullerton authorized distributor to help make this decision. We will work with you to get the end results you desire with a wide variety of both GP and HP end mills available.

We even have some tooling where we apply HP coatings to GP tools to help you get the most out of your cutting tool investments. We have a huge selection of inventory items and of course, if you need a special tailored tool to your specific needs, we have engineering and application knowledge to get the most out of your cutting tool budget.

We also have resources on our website to help you navigate which tool is the best for your needs. Discover what end mills are recommended for your material and application by using the Fullerton Tool End Mill Selection Guide 

You can also explore and search for tooling by material, application, or tool specs as well as 
 recommended speeds and feeds by series which you can access at the search button below.

"Ergo" is a new trademark of Nine9 for ER type indexable cutter. The cutter is assembly kit by the 3 parts including Ergo nut, high strength Ergo pin and Integrated ER taper. Patented design mechanism to produce high clamping Forces and high runout accurancy.

It's perfectly suitable for driven tools and spindles with ER interface of CNC turning centers and swiss type automatic lathes such as Star, Citizen, Tsugami, Doosan, Tornos, INDEX, EMAG and so on.

​The Ergo provides types ER11, ER16, ER20, ER25 taper-shank cutter. The ergo tooling include milling cutter, spot drill, chamfering tool, corner rounding, engraving tool, deburring tool, center drill and boring tool.

by Steven Oszust Jr. at ​Fullerton Tool

This month we will focus on one of our most successful legacy tools, the Fullerton Tool's 3400 Harmon-i-Cut end mill. Nearly two decades ago, we recognized the advancements in machining technology demanded increasingly aggressive machining operations to enhance productivity and reduce production costs.

Advancements in spindle technology enabled greater spindle speeds while maintaining the necessary power to perform more aggressive cutting operations. With the greater acceptance and application of high-speed machining (HSM) practices in programming, spindle speeds were increased to a range which was greater than those traditionally used for an increase in material removal rates (MRR) over traditional tools.

High-speed machining is achieved by increased axial depth of cut and higher spindle speeds, combined with constant chip loads requiring new high-performance tooling design.

One limitation in achievable MRR is self-excited vibrations of the cutting tools, known as chatter. Chatter is caused by variations in the inconsistent chip thickness caused when the vibration of the tooth currently engaged in the cut is out of phase with the vibration of the previous tooth.

Specifically engineered geometries greatly reduce chatter leading to smoother running, faster feed rates. These tools are ideal for all roughing and finishing operations, offering longer tool life and improved surface finishes.

Harmon-i-cut end mills have engineered flute shape designed for maximum rigidity, variable helix, variable rake, superb chip evacuation, and excellent shearing action. Reduced load pressures and super stiff design promotes less chatter, achieving rapid Harmonic-free stock removal at rates never seen before.

By utilizing chip thinning strategies, significant increases in productivity and tool life can be achieved. These methods are also helpful when using machines with less power and stability. Even with weaker machines and less stable working conditions, very high cutting parameters can be achieved.

These strategies are particularly effective for increasing process reliability in difficult to machine materials or challenging applications.

Consider Fullerton Tool's  3400 series Harmon-i-cut a cut above the rest. With our vast inventory of sizes and configurations, we can provide a solution for your needs. Contact Browne Sales to get started

 by Steven Oszust Jr. Product Development Manager/Lead Tool Design Engineer at Fullerton Tool Co.

At Fullerton Tool ,Our primary purpose is to provide our customers with cost-effective, high-quality, solid carbide round tool solutions at competitive prices. In the past we have discussed our consistency in our processes, and foundational approach to tool designs.

These traits can best be described as the basis for Functional Value.

In the case of our general purpose end mills, functional value involves all the core processes and systems that customers are not paying for. These processes and systems are deeply engrained in our culture.

Often development for the higher end, performance side of our offering, these systems naturally trickle down to the general purpose tools automatically in our tool strategy.

The benefits of this tool strategy can be seen in everything we do. The nearly 150 years combined experience in our production engineering team, makes Fullerton one of the most detail oriented companies in the industry. Our innovative manufacturing processes and years of experience ensure the best possible value for cost conscious metalworking consumers. 

Consider our General Purpose End Mills a cut above the rest. With our vast inventory of sizes, configurations, and coatings we can provide a solution for your needs.

Start your search for the perfect General Purpose End Mill on the Fullerton Tool Website or contact your dedicated regional managers at Browne Sales for application recommendations.