Introduction

End mills play a pivotal role in contemporary manufacturing. As a type of cutting tool, they are designed into different types according to processing needs. Among them, corner radius end mills occupy a prominent position in many application fields due to their unique design and performance advantages. This article aims to provide an in-depth explanation of the definition, characteristics, application scenarios, and differences between corner radius end mills and other end mills.

1. Definition of fillet radius end mill

A corner radius end mill is an end mill designed with a small radius on the end edge of the tool. The radius of this fillet is usually between 0.5mm and 3mm, which reduces the stress concentration generated during the cutting process through a smooth transition, thus improving the surface quality of the machined and the durability of the tool.

2. Structure of fillet radius end mill

1. Cutting edge

The cutting edge of a corner radius end mill is spiral-shaped and distributed around the tool. The spiral cutting-edge design helps to effectively remove chips, reduce cutting heat accumulation, and improve processing efficiency.

2. Tool end

The rounded corners at the end of the tool are its distinguishing feature. Rounded corners can alleviate stress concentrations and reduce the risk of tool chipping, thereby extending tool life.

3. handle

The tool handle is the part that connects the tool and the machine. Our common ones are straight, pointed, and threaded. Choosing the right shank will make the tool more stable and the machining more accurate.

3. Characteristics of fillet radius end mills

1. High strength and hardness

Corner radius end mills are generally made of carbide or high-speed steel. These materials are particularly tough and durable. Therefore, this kind of milling cutter can easily handle difficult materials, such as stainless steel, quenched steel, and titanium alloys.

2. Excellent wear resistance

Carbide materials have excellent wear resistance, allowing fillet radius end mills to remain sharp during long periods of high-intensity machining, thereby extending tool life and reducing replacement frequency.

3. Good surface quality

Due to the rounded design, the rounded radius end mill can reduce stress concentration and cutting heat accumulation during the machining process, thereby improving the smoothness and accuracy of the machined surface.

4. Diverse coating options

The layer of stuff coating a ball end mill, such as TiN or TiAlN, doesn’t just look good. They enhance tool durability, protect against oxidation, and keep good performance at high temperatures.

4. Application scenarios of fillet radius end mills

1. Mold manufacturing

In mold manufacturing, corner radius end mills are widely used to machine cavities, slots, and curved surfaces. Its excellent surface quality and high precision make it ideal for mold processing.

2. Aerospace

In the aerospace industry, there are very high standards for precision machining and surface finish of components. Corner radius end mills demonstrate outstanding performance when processing high-strength materials and meet the stringent part quality requirements of this industry.

3. Automobile manufacturing

In automotive manufacturing, corner radius end mills are used to machine engine parts, drivetrain, and chassis parts. Its high efficiency and long life significantly improve production efficiency and reduce manufacturing costs.

4. Precision machining

Precision machining requires high-precision and high-quality cutting tools. Cor radius end mills perform well in the processing of precision mechanical parts and meet the requirements of high-precision machining.

5. The difference between corner radius end mills and other end mills

1. Differences from right-angle end mills

Right-angle end mills have no corner design at the end edge of the tool and are suitable for general surface milling and slot milling. Due to its rounded corner design, the corner radius end mill can reduce stress concentration and improve the quality of the processed surface, making it more suitable for high-precision and high-quality processing requirements.

2. Differences from ball nose end mills

The design of the ball end mill is unique. Its hemispherical cutting edge can easily handle various complex curved surfaces. Corner radius end mills, on the other hand, have small radius edges designed to reduce pressure points and improve the appearance of the finished product. This kind of knife is more suitable for processing flat surfaces or simple curved surfaces.

Conclusion

Corner radius end mills excel in the machining of high-precision, high-quality, and high-strength materials due to their unique design and excellent performance. Through the reasonable selection of tool materials, corner radius, and coating, its processing performance and service life can be further improved. I hope this article can provide a beneficial reference for mechanical processing practitioners and help the smooth progress of production and processing.