What are the Main Types of Milling Cutters According

to Use?
The standard and special milling cutters generally used for normal production are
explained below.

Plain Milling Cutter

The plain milling cutters are cylindrical in shape and have teeth on the circumference
surface only. The cutters are intended for the production of flat surfaces parallel to
the axis of rotation of the spindle. The cutter teeth may be straight or helical according
to the size of the cutter. Over ¾ wide the teeth are usually cut on a helix to give
shearing cut. Very wide plain milling cutters are termed as slabbing cutter. These
cutters have nicked teeth. The object of nick is to break up the chips and enables the
cutter to take a course feed.

Plain and Slab Milling Cutter

Side and Face Cutters
These cutters have teeth on its periphery and also on one side or both of its sides. The
side milling cutters are intended for removing metals from the side of the work. Plain
side milling cutters have straight circumferential teeth and side teeth on both of its
sides, two or more cutters may be mounted on the arbor to mill different faces of work
simultaneously.

Side and Face Cutter

Staggered Teeth Cutter
The staggered teeth side and face milling cutters have alternate teeth with opposite
helix angle. The design of the cutter teeth increases the chip space to a great extent.
The cutter is suitable for milling deep narrow slots or key ways on work. Two side or
two staggered teeth milling cutters are joint together such that their teeth interlock to
form one unit. They may be plain or of alternate helix.

Staggered Teeth Cutter

Slotting Cutter
Cutter having teeth on its periphery and side being relieved. Its diameter does not
exceed 6” and thickness is above ¼. It is used for producing exact slots and grooves.

Slotting Cutter
Slitting Saw
This is thin plain milling cutter of very small width. The sides of the cutter are relieved
in order that the side faces may not rub against the work. The plain metal slitting saw
cutter is limited to 5 mm width. Staggered teeth metal slitting saws are limited to width
6.5 – 7 mm width.
 Slitting Saw
Angular Cutters
They are made as single or double angle cutters and are used to machine angles other
than 90 degree.
(i) Single Angle Milling Cutter - They have teeth on the conical or angular face of the
cutter and also on the large flat side. The angle of the cutter is designated by the
included angle between the conical face and the large flat face of the cutter. The
cutters have different included angles of 30, 45, 60, 70, 75, 80 and 85 degrees are
available with diameters of 50 mm and width of 12 mm. Second set of cutters having
the same range of included angle, but the diameter of the cutter is 63 mm and width
28 mm. Third set of cutters having included angle of 78, 75 and 80 degree. All having
63 in diameters and width of 28 mm.

Single Angle Cutter

(ii) Double Angle Milling Cutter - They have V shaped teeth with both conical surfaces
at angle to their end faces. The angle may not be symmetrical with respect to a plane
at right angles to the cutter axis. The cutters are available in different included angles
of 55, 60, 65, 70, 80, 90, and 100. The equal angle cutters are available in diameters
from 56 to 100 mm having width range from 10 to 28 mm. These cutters are mainly
used for cutting spiral grooves on a piece of blank. Double angle cutter with different
angle and equal angle are shown in figure below.

Double Angle Milling Cutter

End Mill
The end mills have cutting teeth on the end as well as on periphery of the cutter. The
peripheral teeth may be straight or helical. The end mills are used for light milling
operations like cutting slots, machining accurate holes, producing narrow flat surfaces
and for profile milling operations.
(i) Taper Shank End mills - Have a tapered shank on one end for mounting and driving
the cutters. The cutters may be double fluted or multiple fluted. These end mills are
available from 10 – 63 mm in diameter.

Taper Shank End Mills

(ii) Straight Shank End mills - Have round shanks for mounting and driving the cutters.
Cutter teeth may be straight or helical. The diameter of the cutter ranges from 2 to 63
mm.

Straight Shank End Mills

Shell End Mills
Shell end mills are large and heavy end mills provided with a central hole for mounting
the cutter in a short arbor. The cutting edges are provided at the end around the
periphery of the cutter. The teeth may be straight or helical. Face milling operations
are usually performed with these cutters. The diameter ranges from 40 to 160 mm and
width from 32 to 63 mm and bore diameters of cutters range from 16 to 50 mm.
 Shell End Mill
T-Slot Milling Cutter
The ‘T’ slot milling end mills for producing T-slots. The teeth are provided on the
periphery as well as on both sides of the cutter.

T-Slot Milling Cutter

Woodruff Key Slot Milling Cutter
These milling cutters are small standard cutters similar in construction to a thin, small
diameter plain milling cutter, intended for production of woodruff key slots. The cutter
is provided with shank and may have straight or staggered teeth.

Woodruff Key Slot Cutter

Fly Cutter
The fly cutters are similar form of cutters and are mainly used in experimental shops
or in tool room works. The cutter consists of a single point cutting tool attached to the
end of an arbor. The cutter may be considered as an emergency tool when the standard
cutters are not available.

Formed Cutter
This cutter has irregular profiles on the cutting edges in order to generate an irregular
out lines of the work. They are
(i) Convex Milling Cutter - The convex milling cutters have teeth curved outwards on
the circumferential surface to form the contour of a semicircle. The cutter produces a
concave semicircular surface on a work piece. The diameter of the cutter ranges from
50 to 125 mm and the radius of the semicircle varies from 1.6 to 20 mm.

(ii) Concave Milling Cutter - The concave milling cutter has teeth curved upwards on
the circumferential surface to form the contour of a semicircle. The concave milling
cutters produce a convex semicircle surface on a work piece. The diameter ranges from
1.5 to 20 mm.

Gear Cutter

The gear cutter has formed cutting edges which produce shape of the cutter teeth on
the gear blank. The shape of the cutter teeth may be involutes or cycloidal according
to the gear teeth profile. A list of cutter with the number of teeth they are intended
to cut is given in the table.

Gear Cutter
Types of Milling Cutters
Manufacturing Technology / By jaychris / Mechanical Engineering
In manufacturing, milling machines are very important. Aside from
the fact that this machine is used for machining solid materials, a
milling machine is also used for planing, die-sinking, keyway
cutting, and routing, among others. The milling machine provides
convenience to the operator because the workpiece is moved
toward the cutter. In this manner, machining is more effective.

Some of the most important components of the milling machine

are the mill tools. These tools are actually the cutting tools which
are attached to the milling machine for the cutting process. There
are many types of mill cutting tools depending on the shape and
the size. Moreover, milling cutters are categorized according to
coatings and rake angle. The cutting process is achieved by the
movement of the cutter within the machine.

In order to achieve effective cutting, the features of the milling

cutter must be critically considered. The milling cutter features
include shape, flutes, center cutting, helix angle, shank, roughing,
and coatings.

Shape. The shape of the cutter determines the type of cutting

operation it can perform. There are many standard shapes used in
various industries.
Flutes. These are deep helical grooves running up the cutter.
Along the edge of the flutes, sharp blades are located. These
blades are referred to as the teeth and are the components that
cut through the material.
Center Cutting. This is the orientation of the cutting tool which
determines whether the cutting tool can plunge through a
material or not.
Helix Angle. The helix angle sets the gradual entry of the tooth
on the material. Moreover, the helix angle reduces vibration of the
cutting tool.
Shank. This is the cylindrical part of the cutting tool that is
attached to the milling machine and is responsible for holding the
tool in place.
Roughing. A cutter configuration which is composed of serrated
teeth effective for breaking the material into smaller pieces.
Coatings. Coatings are responsible for improving the surface
finish, increasing the speed, and increasing the tool life.
While each of these features dictate the performance of the
cutting tool, the type of cutting done is determined by the various
types of cutting tools as well. The different types of milling cutters
are slot drill, ball nose cutter, slab mill, face mill, and fly cutter to
name a few.

Slot Drill. The slot drill is capable of drilling straight down into the
material. This consists of two flutes, with which one tooth is found
at the center of the end face.
Ball Nose Cutter. This cutter is similar to the slot drill, however,
the end of the cutters are hemispherical. This cutter is most
commonly used in machining three dimensional contoured
shapes.
Slab Mill. Slab mills are typically used for the quick machining of
large broad surfaces.
Face Mill. This type of cutter uses multiple disposable carbide or
ceramic tips mounted on its cutter body.
Fly Cutter. This consists of a single body from which one or two
tool bits are inserted. The individual cutters of this cutter are
replaceable as with the face mills.

Fig.1. Types of Mill Cutters

Fig.2. Face Cutter

Down milling vs. up milling

Each time a milling edge enters a cut, it is subjected to a shock load. The right type of contact between
the edge and material at the entry and the exit of a cut must be considered for successful milling. In a
milling operation, the workpiece is fed either with or against the direction of the cutter rotation which
affects the start and finish of the cut and if down milling or up milling method is used.

The golden rule in milling – Thick to thin

When milling, you always need to consider how the chips are being formed. It is the cutter position that
forms the chips and you should always aim for thick chips on entry and thin chips on exit to ensure a
stable milling process.

Remember the golden rule in milling – thick to thin – to ensure the lowest chip thickness possible when
exiting a cut.
Down milling
In down milling (climb milling), the cutting tool is fed with the direction of rotation. Down milling is always
the preferred method wherever the machine tool, fixture and workpiece will allow.

In peripheral down milling, the chip thickness will decrease from the start of cut, gradually reaching zero
at the end of cut. This prevents the edge from rubbing and burnishing against the surface before
engaging in the cut.

The large chip thickness is advantageous, and the cutting forces tend to pull the workpiece into the cutter,
holding the cutting edge in the cut.

However, as the cutter tends to be pulled into the workpiece, the machine needs to handle the table-feed
play using back-lash elimination. If the tool pulls into the workpiece, feed is unintentionally increased
which can lead to excessive chip thickness and edge breaking. Consider using up milling in such cases.

Up milling
In up milling (conventional milling), the feed direction of the cutting tool is opposite to its rotation.

The chip thickness starts at zero and increases toward the end of the cut. The cutting edge has to be
forced into the cut, creating a rubbing or burnishing effect due to friction, high temperatures and, often
times, contact with a work-hardened surface caused by the preceding edge. All this reduces the tool life.
The thick chips and higher temperature at the exit from cut will cause high tensile stresses that will reduce
tool life and often result in rapid edge failure. It can also cause chips to stick or weld to the cutting edge,
which will then carry them around to the start of the next cut, or cause momentary edge frittering.

Cutting forces tend to push the cutter and workpiece away from each other and radial forces will tend to
lift the workpiece from the table.

Up milling may be advantageous when large variations in working allowance occur. It is also
recommended to use up milling when using ceramic inserts in heat resistant alloys, because ceramics are
sensitive to impact at workpiece entry.

Workpiece fixtures
Feed direction of the tool places different demands on the workpiece fixture. During up milling, it should
resist lifting forces. During down milling, it should resist pulling forces.

SOURCES

http://www.qhunt.com/2016/01/what-are-main-types-of-milling-cutters.html?m=1

http://mindworks.shoutwiki.com/wiki/Cutter_Types_(Mill)

https://www.brighthubengineering.com/manufacturing-technology/66498-milling-
toolsfeatures-and-types/

https://www.sandvik.coromant.com/en-gb/knowledge/milling/pages/up-milling-vs-
down-milling.aspx