Face Mills
A face mill is a milling tool used for the precise machining and flatness of planar surfaces. Typical designs feature cutters with indexable inserts and a 45° setting angle, providing balanced cutting forces and good surface finish.
Choosing the right face mill increases process reliability, material removal performance, and cost efficiency. At METAV, you will find high-quality face mills for precise and economical metalworking – available in a wide range and from renowned manufacturers.
Advantages at a Glance
- High surface finish: 45° face mills produce thinner chips and reduce vibrations.
- Efficiency: Large cutter diameters and multiple cutting edges allow high feed rates and high material removal rates.
- Process reliability: Balanced axial and radial forces reduce stress on the machine and clamping system.
- Versatility: From roughing to finishing – suitable geometries, grades, and indexable inserts are available for every task.
Overview of Face Mill Types
The selection of the appropriate milling type depends on the material, machine performance, desired surface finish, and removal rate.
| Type of Cutter | Properties | Typical Applications |
|---|---|---|
| Indexable Insert Face Mills (45°) | All-rounder; balanced cutting forces; good surface finish | General facing, steel/cast iron/non-ferrous materials, roughing to finishing |
| High-Feed Face Mills (10–30°) | Thin chips, very high feed rates; low radial load | Productive roughing with limited power; stable setups |
| 45° Face Mills with Wiper Corners | Additional wiper geometry for improved surface quality | Finishing operations with high feed rates and required Ra |
| Heavy-Duty Face Mills | Robust cutter body; large cutting depths and feed rates | Coarse pre-machining, high material removal rates, cast iron/steel |
| Special Face Mills (e.g. with cooling channels) | Targeted cooling/chip removal; material- or process-specific geometries | Heat-sensitive materials, long tool life, process stability |
Applications and Fields of Use
Face mills are primarily used for the precise machining of flat surfaces.
- Mechanical engineering: Flatness and parallelism on large components and flanges.
- Automotive industry: Series production with high material removal on housings and heads.
- Aerospace industry: Light metals with high surface quality and minimal burr formation.
- Tool and mold making: Roughing and finishing of mold plates and clamping surfaces.
- General metalworking: Slot facing, preparation for sealing surfaces, and assembly areas.