Some people think of face mills as large diameter tools with lots of inserts. These kinds of face mills need big spindles to push them efficiently, but a fly cutter provides an effective way to face on low horsepower spindles and can deliver superior surface finishes - here's why:
Fly cutters have previously been known as tools for manual machinists, but as Bob Warfield at CNC Cookbook explains, “Many CNC machinists realize that a very fine surface finish may be better done by fly cutting.”
While face milling provides a quality surface finish at higher speeds, a fly cutter can create a much finer finish because you are only cutting with one insert. Face mills use multiple inserts, which allow for more removal of material, but unless you’re spending a significant chunk of change, the height of the inserts can’t be individually adjusted, causing varying chipload among the different inserts. A fly cutter provides a single cutting surface, which isn’t as fast but is much more uniform and develops into a smoother surface.
Cost can also be a factor. We’ve seen Tormach customers use large face mills on their machines, but those tools are expensive – and so are the inserts at $10-$20 each. If you have upwards of $600, or much more, to spend and customers waiting on parts, a face mill might be the route to go.
But if you’re looking to get fantastic surface finishes and speed per operation isn’t as much a factor, you can pick up the TTS Superfly cutter stocked with inserts for both softer materials (like aluminum) and harder materials (like steel) for less than $150. As with most things in machining, there are many different ways to do face milling and create impressive surface finishes, but it’s all about calculating how much time and money you’re willing to invest in your part.
FAQs
Fly cutters utilize one or two inserts at a lesser cutting speed to remove excess workpieces during milling operations. In comparison, face mills employ multiple inserts at a higher cutting speed, making them more suitable for heavy material removal.
Is a fly cutter better than a face mill surface finish? ›
While face milling provides a quality surface finish at higher speeds, a fly cutter can create a much finer finish because you are only cutting with one insert.
How deep can you cut with a face mill? ›
Face milling with a very high feed per tooth (up to 4 mm/tooth) is possible when using cutters that have small entering angles, or when using round insert cutters, due to their chip-thinning effect. Although the depth of cut is limited to less than 2.8 mm, the extreme feed makes it a highly productive milling method.
What is the facing operation of milling? ›
Face milling operation
Facing on a milling machine is the process of cutting a flat surface perpendicular to the axes of the milling cutter. This process removes the material by rotating the facing tool in the counterclockwise direction as the table feeds the work piece across the cutter.
What are the disadvantages of cutter mill? ›
Disadvantages: More space than other mill, Contamination, Time consuming, Not use for sticky materials. Principle: Size reduction is done by crushing due to heavy weight of steel pestle.
What is the difference between a face mill and a flat end mill? ›
The most significant difference between face milling and end milling is the cutting tool used. Face mills have a design that only allows them to cut perpendicular to the tool spindle axis. End mills, on the other hand, have cutting edges on both the end and sides of the cutting tool.
What is the most preferable milling technique? ›
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.
Which milling gives better surface finish? ›
Climb Milling is generally the best way to machine parts today since it reduces the load from the cutting edge, leaves a better surface finish, and improves tool life. During Conventional Milling, the cutter tends to dig into the workpiece and may cause the part to be cut out of tolerance.
What are the advantages of a fly cutter? ›
One of the main advantages of using a fly cutter is that it can create a very smooth surface finish on a workpiece. It is also a relatively simple and inexpensive tool to use, making it a popular choice for many manufacturing applications.
What is the cutting speed of face milling? ›
The cutting speed is 137.4m/min.
The purpose of face milling is to create a flat surface on the workpiece, achieved by cutting with the ends of the cutter rather than the sides. This process is essential for achieving precise, flat, and smooth surfaces on materials, such as plates or bars.
What is the theory of facing operation? ›
Facing is an operation of machining the end of a workpiece that is perpendicular to the rotating axis. During the facing, the tool moves along the radius of the workpiece to produce the desired part length and a smooth face surface by removing a thin layer of material.
What is the cheapest type of milling operation? ›
The Plain Milling or Slab Milling is the most cost-effective one. It involves simple cutters and a straightforward material removal mechanism from a flat surface. However, you can not create intricate shapes only with this operation.
What is the lead angle in face milling? ›
The lead angle of a face-milling cutter is the approach angle of the cutting edge in relationship to the workpiece and is measured off the axis of the cutter. The lead angle's relationship to the cutter and spindle axis impact tool performance and productivity significantly, which in turn affects workpiece quality.
What is a fly cutter for a mill? ›
Fly cutters are used primarily on a milling machine for machining large, flat surface areas. The fly cutter is a single-point cutting tool similar to a lathe tool mounted in a special holder. The cutter can be adjusted to cut up to a 2.00″ (51 mm) diameter and is easily capable of taking a .
What is the difference between face milling and side milling? ›
When compared to face milling, peripheral milling is more effective at removing large amounts of material from workpieces. This is because it uses the sides of the milling cutter rather than the tip. With face milling, only the tip of the cutter is exposed to the workpiece.
Why is it called a fly cutter? ›
The general definition of a fly cutter is a tool holder for a single-point cutting tool that sweeps the tool in a circle over the surface of a fixed workpiece. The tool flies over the work, unlike a conventional single-point lathe tool, where it is the work that moves.
What are the two basic types of milling cutters and their functions? ›
These are two of the most prevalent milling operations, each using different types of cutters – the and mill and the face mill. The difference between end milling and face milling is that an end mill uses both the end and the sides of the cutter, whereas face milling is used for horizontal cutting.
