Face milling

The machining industry uses a number of different processing techniques to produce high quality components. Face milling brings with it various challenges. We will give you an overview of the practice and the associated requirements..

You can find all our face milling cutters here.

What is face milling and which factors have to be considered? Here are some aspects that contribute to a successful finish.

In the process of face milling, a rotating tool ensures that material is removed from a component to create a flat surface. Typically, indexable insert milling cutters are used for this purpose. In this context, productivity, measured in terms of metal removal rate, and the quality of the resulting surface, measured in terms of roughness, are of particular importance.

When using a face milling cutter, an inclined cutting edge often proves useful. The angle at which the cutting edges engage has a direct influence on the alignment of the cutting forces. An angle of attack of about 45° is often considered the optimum balance, as this distributes the forces evenly between the transverse and axial forces. The partial redirection of the cutting forces in the direction of the spindle can lead to a considerable increase in productivity. For thin-walled components, an angle of attack of 90° is advisable to reduce the pressure on the component. Milling cutters with round inserts are an alternative. These round inserts flexibly direct the flow of force depending on the depth infeed. A depth of cut equal to half the diameter of the insert corresponds approximately to an approach angle of 45°.

What are face milling cutters

Face milling cutters are specialised tools that are used to machine metals, creating even and precise surfaces. They are available in a variety of shapes and dimensions and are often used in CNC milling machines to create complex shapes and surfaces.

A face mill consists of a cylindrical body that carries cutting edges on its top. These cutting edges can be either straight or angled and are usually made of carbide to ensure a high degree of abrasion resistance and durability. The cutting edges are placed in a specific arrangement on the cutter to achieve the desired surface finish.

Face milling cutters are used in a variety of applications, such as producing flat surfaces, grooves, teeth in gear wheels and other precise shapes. They can also be used to roughly machine material to remove large amounts of material quickly.

When using face milling cutters, it is essential to select the appropriate cutting speed, feed rate and chip evacuation to achieve the best quality of finish and maximise the life of the tool. It is therefore essential that trained and experienced professionals operate these tools to achieve the best possible results.

In summary, face milling cutters play a central role in metalworking and are particularly suitable for precision-intensive machining operations. Although more complicated than conventional cutters, they can deliver outstanding surface quality and accuracy when used correctly.

Metav Werkzeuge offers an extensive range of face milling cutters in its product range. Do you need assistance with face milling? Don't hesitate to contact us and we will be at your side.