Mapúa Institute of Technology

658 Muralla St, Intramuros, Manila, 1002 Metro Manila

School of Mechanical and

Manufacturing Engineering

MFGE09L – ENGINEERING METROLOGY

Technical Report No. 3

END MILL

Name: Espaldon, John-mark S. Date Conducted: August 23, 2019

SN. 10 Date Submitted: September 6, 2019
Student No. 2013106984

Score

Engr. Sublime Carvajal

Instructor
 Table of Contents

I. Table of Contents 1
II. Objectives 2
III. Theory/Hypothesis 2
IV. Introduction 4
V. Discussion 5
VI. Conclusion 8
VII. Recommendation 8
VIII. References 9
 I. OBJECTIVES
1. To utilize the digital caliper in obtaining the needed measurements from
the end mill.
2. To utilize the engineers’ protractor in obtaining the needed angles from
the end mill.
3. To be able to understand the parts of the end mill and to determine the
needed measurements by applying what is discussed during the
discussion.

II. THEORIES AND HYPOTHESSIS

End milling is the most versatile form of milling that can be used to machine
slots, shoulders, die cavities, contours, and profiles. An end milling process
consists of a cylindrical cutter that has multiple cutting edges on both
its periphery and its tip, permitting end cutting and peripheral cutting. These
cutting edges or flutes are usually made helical to reduce the impact that occurs
when each flute engages the workpiece. In this section, a theoretical model for
cutting forces in helical end milling is developed based on Oxley's predictive
machining theory.

A variety of grooves, slots, and pockets in the workpiece may be produced

from a variety of tool bits. Common tool bit types are square end cutters, ball end
cutters, t-slot cutters, and shell mills. Square end cutters can mill square slots,
pockets, and edges. Ball end cutters mill radiused slots or fillets. T-slot cutters mill
exactly that: T-shaped slots. Shell end cutters are used for large flat surfaces and
for angle cuts. There are variations of these tool types as well.

There are four critical angles of each cutting tool: end cutting edge angle, axial
relief angle, radial relief angle, and radial rake angle.

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Depending on the material being milled, and what task should be performed,
different tool types and geometry may be used. For instance, when milling a
material like aluminum, it may be advantageous to use a tool with very deep,
polished flutes, a very sharp cutting edge and high rake angles. When machining a
tough material such as stainless steel, however, shallow flutes and a squared-off
cutting edge will optimize material removal and tool life.

A wide variety of materials are used to produce the cutting tools. Carbide inserts
are the most common because they are good for high production milling. High
speed steel is commonly used when a special tool shape is needed, not usually used
for high production processes. Ceramics inserts are typically used in high speed
machining with high production. Diamond inserts are typically used on products
that require tight tolerances, typically consisting of high surface qualities
(nonferrous or nonmetallic materials). In the early 90s, use of coatings to reduce
wear and friction (among other things) became more common. 

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 III. INTRODUCTION
End mills are the most common milling cutters. End mills are available in a
wide variety of lengths, diameters, and types namely:
 A square end mill is used for most general milling applications. It
produces a sharp edge at the bottom of pockets and slots. End mills
can be center cutting and non-center cutting. As their name implies;
 center cutting end mills have cutting edges on both the end face of the
cutter and the sides. Center cutting end mills are essential for plunge
milling;
 Non-center cutting end mills have cutting edges only on the sides and
are used only for side milling. These tools are identified by a small
hole at the center.
 Roughing end mills have serrations in the teeth to quickly remove
large amounts of material without creating vibration. The serrations
produce many small chips and a rough finish;
 Ball end mills produce a radius at the bottom of pockets and slots.
Ball end mills are used for contour milling, shallow slotting, contour
milling and pocketing applications.

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 IV. DISCUSSION
For this experiment, we utilized the use of a digital caliper and
engineering protractor to measure the critical dimensions of an end mill.
With the guide of our instructor, we were able to determine 5 critical
dimensions for each student of the said end mill.
To determine which parts has the critical dimensions, we researched
for the important factors considered in using an end mill. These are the end
mill materials, coatings, flute number, feed rate, and cutting speed.
Materials
End mills are made from either cobalt steel alloys (known as high speed
steel, or HSS), or from tungsten carbide in a cobalt lattice (shortened to "carbide").
 High Speed Steel (HSS): Provides good wear resistance and costs less
than cobalt or carbide end mills. HSS is used for general purpose milling of both
ferrous and nonferrous materials. While usually inexpensive, HSS does not offer
the tool life or speed advantages of cobalt and carbide end mills.
 Cobalt: Cobalt is an M42 tool steel with an 8% cobalt content. Cobalt is
more expensive but provides better wear resistance and toughness than HSS (M7).
Because the tool can run 10% faster than HSS, metal removal rates and finish are
better than HSS.
 Solid Carbide: Carbide is considerably harder, more rigid, and more wear
resistant than HSS. However, carbide is brittle and tends to chip instead of wear.
Carbide is used primarily in finishing applications. Carbide tools are best suited for
shops operating newer milling machines or machines with minimal spindle wear.
Rigidity is critical when using carbide tools. Carbide end mills may require a
premium price over the cobalt end mills, but they can also be run at speeds 2 1/2
times faster than HSS end mills.

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The choice of tool material depends on the material to be cut as well as on the
maximum spindle speed of the machine. Smaller milling machines may not be
capable of reaching the spindle speeds recommended for carbide end mills.
Coatings
The use of coatings will increase the surface hardness of the tool. This will allow
for greater tool life and faster cutting speed. Standard coatings include Titanium
Nitride (TiN), Titanium Carbonitride (TiCN), and Aluminum Titanium Nitride
(AlTiN).
 Long-life TiN (titanium nitride) coating is good for use on alloy steel,
aluminum, and plastic. Color is gold.
 Extra-life TiCN (titanium carbonitride) coating has better wear resistance
than TiN coating, making it a good choice for tough-to-machine materials
such as ductile cast iron, stainless steel, aluminum, and plastic. Color is blue
gray.
 Super-life AlTiN (aluminum titanium nitride) coating is the best for very
high feeds/speeds and high-temperature applications. Use to mill cast iron,
stainless steel, nickel-based alloys, and titanium. Not for use on aluminum.
Color is purple gray.
The choice to use coated end mills is a cost versus benefit choice. If your
machining benefits enough from the extra performance of a premium coating,
purchase end mills with a coating.
Cutting Speed
Cutting speed is a velocity unit expressed in terms of revolutions per minute
or surface feet per minute. This is the speed that the cutting edge moves past the
material. Revolutions Per Minute (RPM) relates directly to the speed, or velocity,
of the tool spindle. It annotates the number of turns completed in one minute

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around a fixed axis. RPM maintains the same revolutions per minute throughout
the entire operation.
Surface Feet Per Minute (SFM) is a combination of the tool diameter and
RPM. The faster the spindle turns, and/or the larger the tool diameter, the higher
the SFM. If two cutters of different sizes are rotating at the same revolutions per
minute, the cutter with the larger diameter results in a greater cutting speed
because it has a larger circumference and has more surface area. Materials will run
better at specific SFMs. SFM is a constant, with RPM as a variable based upon tool
diameter. When the SFM constant is known for a specific material, the formulas
below can be used to determine spindle speed for milling various materials.
RPM = SFM x (12/Pi) / Tool Diameter
So, for an SFM of 400 and a tool diameter of 1/2", RPM can be found:
RPM = 400 x 3.82 / 0.5 = 3056 RPM
The calculation of SFM is the opposite:
SFM = RPM x Tool Diameter x Pi/12
Feed rate
Feed rate is the velocity at which the cutter is advanced along the workpiece. Feed
rate is expressed as units of distance per minute or distance per tooth (chip load).
Feed rate can be defined as Inches Per Minute (IPM) or Inches Per Tooth (IPT).
IPT, or chip load, is more commonly used. Values for IPM and IPT are easily
converted with the following formulas:
IPM = RPM x IPT x Number of Flutes
IPM = RPM x IPT x Number of Flutes

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 V. CONCLUSION
While executing the exercise, we acquired the necessary measurements for
us to make the mechanical drawings of the end mill assigned to our group. The
digital caliper was used well because the needed measurements were obtained.
Individually, I realized that there are different kinds of end mills because every
group has a different kind of milling cutter. Moreover, our group utilized the
engineers’ protractor in obtaining the needed angles. Summing it up, this is a
result-wise exercise because our group were able to achieve the objectives.

VI. RECOMMENDATION
I would like to recommend that the school provide recent tools and equipment
because I think the some of the materials that we used are old. Moreover, I would
like to recommend the students to be more focused while the instructor is teaching
so errors will be minimized, and the students will know what to do.

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 VII. REFERENCES

http://www.wisegeek.com/what-is-a-friction-gear.htm#\

https://itp.nyu.edu/fab/reinventing-the-wheel/week-3/

http://www.codecogs.com/library/engineering/theory_of_machines/the-geometry-
of-gears.php

http://ahmadmujahidin.blogspot.com/2014/05/gear_29.html

https://en.wikipedia.org/wiki/Cycloid_gear

https://en.wikipedia.org/wiki/Involute_gear

http://khkgears.net/gear-knowledge/abcs-gears-b/basic-gear-terminology-
calculation/

http://machinedesignindae.blogspot.com/2011/02/system-of-gear-teeth.html

https://www.machiningcloud.com/wp-
content/uploads/2016/05/MachiningCloud_MillingToolsAndTheirApplication.pdf

https://en.m.wikipedia.org/wiki/End_mill

https://www.sciencedirect.com/topics/engineering/end-milling

https://www.cgstool.com/blog/what-is-end-milling/