End Face Milling Machine Manifacturer

SENLISWELD is your unpredictable End Face Milling Machine manufacturer. Our company owns a professional production team with over 10 years’ experience in producing quality outputs.

  • Provide different types of milling cutters categorized based on special according to your specific needs.
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  • We repeatedly test before delivery in order to make the device more accurate.
  • Provide a one-year warranty after-sales service just to better your business.

End Face Milling Machine

The End Face Milling Machine is used for machining workpieces with irregular surfaces, which can be made into a horizontal or vertical plane by the milling process.

SENLISWELD has many different kinds of milling cutters and provides milling cutters that can minimize the occurrence of breakage. We are always here to provide you with whatever help you need to keep your project going smoothly anytime.

How Does The Milling Process Work?

The milling process basically involves the reshaping of a metal workpiece through cutting and reaching a desired final shape and size.

In the modern milling process, this cutting process is achieved by cutting with metal cutter heads. The metal cutting heads have multiple cutting edges that cut the materials. The cutter is attached with a rotating spindle.

The spindle is located on the top of the workpiece, and you can mechanically rotate it at high speed with the control system. While the cutters are rotated at high speed, you have to feed the workpiece forcefully against the cutter at an optimum rate. A typical face milling operation

When the cutting edge touches the workpiece, it cuts small portions of the workpiece chip by chip until you continue to rotate the cutter and feed the workpiece. Most of the time, the position of the rotating cutter remains in a fixed position, and the workpiece gets fed against, while sometimes it is the opposite.

This is how the basic milling processes work. But during this process, the cutter edge gets in high frictional contact with the workpiece. So, you can observe frequent chatter and vibration problems during the process.

Figure 1 - A typical face milling operation
Figure 4 - Comparison Between The Processes Involved In Plain Milling And End Milling

What Is The Difference Between Plain Milling And End Milling?

The main difference between the plain and the end milling is the difference in the direction of the cutter axis that it makes with the workpiece.

In plain milling, the axis of the cutting head remains parallel to the workpiece on which you want to perform the milling operation. So, when you rotate the cutting head at high speed, each cutting edge chips away small particles of materials parallelly from the workpiece.

Due to the peripheral cutting edges with a horizontal milling function, the circular cutter maintains peripheral contact with the workpiece. So, the edges where you perform the milling operation provide a smooth, gradual finishing in a straight line.

On the other hand, in the end milling, the axis of the cutting head remains perpendicular to the workpiece on which you want to perform the milling operation. So, when you rotate the cutting head at high speed, each cutting edge chip aways small particles of materials perpendicularly from the workpiece.

Due to the presence of both the peripheral and end cutting edges with a vertical milling function, the edges where you perform the milling operation provide a sharp finishing of depth in a circular pattern following the radius of the cutter head.

What Is A Vertical Milling Machine?

The vertical milling machines have spindles directed perpendicularly on the workpiece on which you are performing the milling operation. To adjust the workpiece, you can also adjust the angle of contact of the cutting head.

The common cutting head that you can commonly use with a vertical milling machine are end milling cutter and face milling cutter.

A Typical Vertical Milling Machine
End Mill And Face Mill Cutter

What Is The Difference Between End Mill Cutter And Face Mill Cutter?

You have to use the vertical milling machine to use both the end mill cutter and the face mill cutter. But using the two different types of cutters, you can perform different kinds of milling operations.

The end mill cutters have two sets of cutting edges, in the peripheral direction and the axial direction. So you can cut in two different directions simultaneously, following how you set the direction of workpiece feeding. So, you can produce slots, grooves, or keyways.

On the other hand, the face milling operation is the simplest milling operation. There is a single set of cutting edges, and you cannot perform cutting in the axial direction compared to the end mill.

What Kind Of Surface Finishing Can I Expect From The End Milling And The Plain Milling?

There are differences in the cutting heads’ directions during the end milling and plain milling operations. Due to the differences in cutting edges, you can observe differences in the pattern of surface finishing, which affect the quality of finishing.

When you are performing an end milling operation, you can observe cylindrical marks if you closely observe the finished surface. On the other hand, you can observe parallel patterned marks if you perform plain milling operations.

Expected Surface Finishing With Different Types Of Cutter
Standard Feed-Rate Adjusted With Materials

How Does The Feed Rate Of The Workpiece Affect The Milling Operation?

The feed rate of the material depends on the hardness and directly affects the production time of your milling operation. As a standard, you can follow these specific feed rates for a specific type of materials.

End Face Milling Machine: The Ultimate FAQ Guide

The process of a milling operation is fundamental in the world of manufacturing and production facilities.  The automatic milling operations performed by milling machines are done smoothly within a concise instance of time.

So, it is essential to know the basics of an end face milling machine before implementing it for your business operations. This FAQ guide will answer your common questions on the end face milling machine.

What Is An End Face Milling Machine?

The milling process involves the machining of irregular surfaces of a workpiece. The irregular side of the workpiece might sometimes be a flat curve or other irregular shapes that you need to undergo machining by feeding through the machine.

The machine unit consists of metal cutters that rotate at high speed to achieve the cutting process. Due to the motor-driven high-speed feature with multiple cutting edges, with the end milling operation, you can produce a flat surface that may be vertical, horizontal, or at an angle in reference to the work surface.

What Are The Important Parts Of A Milling Machine?

A typical milling machine has several important parts. Each of the parts is important to function individually their own functions. But collectively, they perform a single function in a synchronized fashion. The important parts are:

Typical Parts Of A Milling Machine
Typical Parts Of A Milling Machine

Base:

  • The base supports the weight of the whole unit and balances, including the workpiece’s weight during the welding operation.
  • They are made of durable materials, typically made of iron, to provide heavy-duty support.
  • In some machines, the bases are designed as a hollow frame to act as the cutting fluid reserve tank.

Column:

  • The main supporting frame is mounted with the base and holds all the key driving mechanisms for the spindle and the feeding table.
  • It holds the knee part that is sufficient to support the knee during the high vibration occurring during your milling operation.
  • The spindle and the arbor are attached to the top part of the column that you can adjust according to the position of the workpiece.

Knee:

  • The knee part is attached to the column piece and adjustable.
  • You can lift up and down the knee piece to adjust according to your convenient position.
  • The feeding mechanism rests on the knee part to form a guiding so that you can slide the workpiece through the working platform.

Saddle:

  • The saddle is positioned on the knee.
  • Depending on the feature provided by the machine, you can use manual or mechanical power to slide the saddle horizontally and support the working platform.

Table:

  • The table is the main working platform where you have to place the workpiece to perform the milling operation.
  • The table is positioned on top of the guideways that are attached to the saddle. You can shift this longitudinally to get flexibility.
  • Once the positioning of the workpiece is complete, with the provided clamping system, you can clamp the workpiece.

Overhanging arm:

  • The overhanging arm will support the arbor piece for you from the top side of the column.
  • You can support the other end of the arbor with adjustment features to support a position closer to the cutter.

Spindle:

  • The spindle part received mechanical force from the machine unit through a gear or belting system and transferred this power to the arbor system.
  • This part is very important as to how accurately and higher quality of work you want as output depends on the strength, accuracy, and rigidity of the spindle.

Arbor:

  • This is the main part that holds the rotational machine cutter for you.
  • They will sincerely mount the cutting head when it is rotated at high speed during the milling operation.
What Are The Types Of Milling Cutters?

There are different types of milling cutters categorized based on special features.

According to the constructional feature of the cutter, the common types of milling cutters are:

  • Solid milling cutter.
  • Inserted teeth milling cutter
  • Tipped solid Milling cutter

According to the relief characteristics of the cutter, there are two types of milling cutters, which are:

  • Profile relieved milling cutter
  • Form relieved milling cutter

The cutter is mounted with the machine unit in different ways. According to the technique with which you can mount the cutter with the machine unit, the types of the cutter are:

  • Arbor-type milling cutter
  • Facing-type milling cutter
  • Shank-type milling cutter

According to the direction of rotation of the cutting teeth, the types of milling cutters are

  • Right-hand rotational cutter
  • Left-hand rotational cutter

According to the direction of the helix of the cutter teeth, there are four types of cutter. These are:

  • Parallel or straight teeth cutter
  • Right-hand helical cutter
  • Left-hand helical cutter
  • Alternate helical teeth cutter

Based on the purpose of the cutter, there are two types of milling cutters

  • Standard milling cutter
  • Special milling cutter
How Can I Avoid End Mill Cutting Tools From Breaking?

First of all, you must remember that you might often break your cutting tools during the milling operations, which is a normal phenomenon even if you follow all rules perfectly. But there are some factors which might help you to keep the breakage from happening.

  • Always start with a lower feed rate of the workpiece on new machines.
  • Adjust the feed rate depending on the type of material you use. On harder materials like aluminum or steel, you have to provide lower feed rates, and on softer materials like plastic or wood, you can provide higher feed rates.
  • Choose a short-tipped cutting head.
  • Use adaptive clearing space and cooling lubricants during the milling operation.
  • Adjust to adequate RPM for the cutting head.

 Common Breaking Concerns With Cutting Tools
Common Breaking Concerns With Cutting Tools

Here is a video that can help you with these beneficial factors.

Why Should I Use Coolants And Cutting Lubrications During Milling Operations?

Cooling and cutting lubricants are very important during milling operations. You should use them since they help you with:

  • Chips can weld themselves with the cutting edges. The lubricants help you to avoid this incident.
  • It will help to remove the newly formed chips out of the milling hole.
  • Provide lubrication.
  • Keep the milling surface cool, ensuring a better milling operation.
Standard Feed-Rate Adjusted With Materials What Materials Are Used For Manufacturing Durable Cutting Tools In Milling Machines?

Common materials that manufacturers utilize to ensure the durability of the cutting tools in milling machines are:

  • High-speed steel alloys are used to provide lasting hardness until 600 ℃.
  • Cemented carbides can provide hardness until the temperature of 900 ℃.
  • Cutting ceramic is even harder than cemented carbides but with a lower toughness aspect property.
  • Carbon steel is a cheaper option, and you can only use them for low-speed operation up to 200 ℃.
Does The Material And Properties Of The Cutting Tool Affect The Cutting Speed During Milling Operations?

Yes, the material of the cutting tools affects the cutting speed. So, you have to consider these aspects for the materials and properties of the cutting tools:

  • Diameter of the cutting tool
  • The coating on the exterior surface
  • Number of flutes or channels on the milling bit
  • Angle of helix
How Does The End Milling Process Work?

The specialty in end milling is in the cutting head. Sometimes you can find a cutting edge on the sides with a flat bottom in these cutting heads. But frequently, you can find cutting edges both at the sides and at the bottom.

Both sets of edges have an individual continuation of the cutting edges. There remains a sharp lining between the ending of the bottom and the side cutting edges. The bottom cutting edge is a slightly radiused cutter to assist you during the cutting operation in the axial direction.

When you feed the workpiece against the rotating cutter, the chipping away of metals is mostly focused on the center of the axial cutter. The chipped-away material is gradually moved upward with the slightly radiused cutter.

Now comes the function of the side cutting edges. When you perform the milling operation and the axial cutting, you can also perform lateral side cutting with the side cutting edges.

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