Comparison between High Feed Milling Cutters And Conventional Milling Cutters

High feed milling cutters are great for roughing, especially in difficult-to-cut materials. Titanium and nickel alloy aerospace structures, mold and die machining are some of the major applications for high feed milling cutters. The smaller entering angle directs the cutting forces in the axial direction of the tool, reducing the occurrence of cutter body deflection. This reduces vibration and chattering while enabling high overhang machining applications.

High Feed End Mills vs. Conventional End Mills

When comparing high feed end mills to conventional end mills, you will notice some differences that help us understand the usefulness of these tools.

Feed Rates and Material Removal Rates:

High Feed End Mills: They have higher feed rates, typically between 0.04 and 0.12 inches per tooth (IPT). This significantly increases material removal rates.

Conventional End Mills: They have relatively low feed rates of around 0.002 – 0.02 IPT, which can hinder effective material removal.

Depth of Cut:

High Feed End Mills: Shallow depths of cut, typically between 0.01 – 0.08 inches, are used here to control cutting forces and enable higher feed rates.

Conventional End Mills: These tools are best suited for depths of cut ranging from 0.1 to 1 inch, depending on tool diameter and material being machined.

Cutting Forces and Tool Life:

High Feed End Mills: They distribute the load evenly across the insert, reducing the forces required to cut while also extending tool life.

Conventional End Mills: Due to the deeper depth of cut, conventional end mills experience higher cutting forces, resulting in increased wear rates and reduced life.

Surface Finish:

High Feed End Mills: Favor smooth surface finishes due to effective chip evacuation and optimized cutting conditions.

Conventional End Mills: A variety of surface finishes are available depending on cutting conditions or depth variations.

Applications:

High Feed End Mills: Suitable for contouring, grooving, and high-speed machining where productivity/accuracy is paramount.

Conventional end mills – More versatile than any other type; they can be used for general-purpose milling, including removing heavy material through deep slots or pockets.