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.
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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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
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