Views: 0 Author: Site Editor Publish Time: 2025-07-15 Origin: Site
Milling cutters with a smaller blade diameter than the shank diameter (also known as "neck milling cutters" or "reducing milling cutters") have significant advantages in specific processing scenarios. Their core benefits are mainly reflected in the following aspects:
1. Interference avoidance ability
Advantage: The blade diameter of the tool is smaller than the shank diameter (such as D1 < D2), which can avoid collision between the shank and the side wall of the workpiece when processing deep cavities, complex contours or narrow areas.
Application scenarios:
Mold processing (such as deep cavities, rib structures).
Aerospace parts (such as impellers, casings and other complex curved surfaces).
When multi-step workpieces need to be milled in layers, the number of tool changes is reduced.
2. Rigidity improvement and vibration control
Advantage: A larger shank diameter (such as D2 > D1) means a thicker shank, which can improve the rigidity of the tool and reduce the deflection caused by cutting force.
Effect:
More stable cutting, especially suitable for high-hardness materials (such as titanium alloys and hardened steel).
Reduce the risk of vibration, improve surface finish, and extend tool life.
3. Adaptability to deep cavity processing
Advantages: Small blade diameter allows the tool to penetrate into narrow areas, while large shank diameter ensures stability when the overhang is long.
Typical applications:
Deep hole and deep groove processing (such as cooling water channels for automotive molds).
Occasions where long overhangs are required (precision can still be maintained when L/D>5).
4. Chip evacuation optimization
Advantages: Small blade diameter means that the cutting groove space is relatively loose, and the large helix angle design can improve chip evacuation.
Effects:
Reduce chip blockage and reduce heat accumulation.
Suitable for efficient processing of sticky materials (such as aluminum alloys and stainless steel).
5. Economy and flexibility
Advantages: Multi-diameter processing is achieved through a single tool (such as using the same tool holder with modular tool heads of different blade diameters).
Cost savings: Reduce tool inventory and avoid customizing non-standard tools for special working conditions.
Limitations to note
Cutting parameter adjustment: Small blade diameters require a reduced feed per tooth (fz) to avoid overload.
Applicable machine tools: rely on high-rigidity spindles (such as machining centers) to play their advantages, and ordinary milling machines may have limited effects.
Summary of selection recommendations
Preferred scenarios: deep cavities, complex contours, high rigidity requirements or long overhang processing.
Alternative solution comparison: If space permits, solid carbide tools (equal diameter design) may be cheaper, but neck milling cutters are irreplaceable in avoiding interference.
By making reasonable use of the difference between blade diameter and shank diameter, this type of milling cutter can significantly improve efficiency and quality in precision machining.