Kunshan Meiyaxing Hardware & Machinery Co., Ltd. is a service-oriented enterprise specializing in the sales and management of CNC cutting tools. We offer a wide range of products, including tungsten carbide end mills and indexable inserts-such as milling, turning, grooving/parting, drilling/boring, multifunctional, and threading inserts-along with their corresponding tool holders and cutter bodies. We have established long-term, stable strategic partnerships with renowned manufacturers dedicated to the R&D and production of high-efficiency tungsten carbide end mills. Our company is equipped with advanced production machinery-such as Swiss ROLLOMATIC, German WALTER, and Japanese MAKINO SEIKI systems-and precision inspection equipment, including the German ZOLLER Genius 3S and American PG 1000. By combining our service and operational expertise with robust R&D and production capabilities, we provide manufacturing enterprises with solutions to various tooling challenges. We aim to serve as a professional partner offering 'comprehensive tooling solutions and cost-optimization services,' focusing on optimizing processing costs to achieve mutual benefit and shared growth.
'Decimal-point' tungsten carbide end mills (typically referring to micro carbide end mills with diameters ranging from 0.3mm to 3mm) act as the 'scalpels' of the precision machining world; they are specifically designed for milling intricate mold features, electronic components, medical devices, and other micro-structures. Due to their extremely small diameters, the operational logic differs significantly from that of conventional end mills: rigidity is the greatest enemy, and chip evacuation is the greatest challenge.
The following discussion covers three key dimensions: tool selection and matching, parameter settings, and workholding/cooling.
I. Tool Selection and Matching: The Logic of Coatings and Flute Counts
When selecting micro end mills, the primary consideration is the material being machined, not the price.
1. Coatings Determine Tool Life
For the finishing of hardened steel (HRC 50 or higher), AlTiN (Aluminum Titanium Nitride) or AlCrN (Aluminum Chromium Nitride) coatings must be selected." ...coating. This coating forms a protective aluminum oxide film at high temperatures, offering oxidation resistance up to 900°C and effectively preventing rapid tool wear caused by heat accumulation during high-speed cutting. When machining soft materials like aluminum alloys, uncoated or DLC-coated tools should be selected; the sharp cutting edge helps prevent built-up edge (BUE) formation and avoids chip clogging in the flutes, which could otherwise lead to tool breakage.
2. Number of flutes determines chip clearance space
Micro end mills have very small chip flutes. A 2-flute mill offers the most chip clearance space, making it the preferred choice for machining aluminum alloys and deep slotting. A 4-flute mill offers superior rigidity, making it suitable for finishing hardened steel; however, it requires high-pressure coolant or compressed air for chip evacuation. Without this, chips can easily become compacted in the flutes, causing the tool to snap.
II. Parameter Settings: A "Dimensional Strike" to Prevent Chipping
Micro end mills are highly susceptible to breakage from overloading. Many operators habitually apply cutting parameters intended for larger tools, which is a primary reason for chipping occurring after only a short period of use.
1. Spindle speed and cutting speed
Do not blindly increase spindle speed simply because the tool is small. Taking 45# steel as an example, the recommended cutting speed (Vc) is 80–120 m/min. For a 1 mm diameter end mill, this translates to a spindle speed of 25,000–38,000 rpm. If the machine spindle cannot reach this speed, the feed rate must be reduced; otherwise, the chip thickness per tooth becomes excessive, and the tool will snap due to the inability to withstand the bending stress.
2. Feed per tooth (fz)
This is the most critical parameter. The feed per tooth for micro end mills is typically only 0.002–0.010... ...mm/z (approximately 2–10 microns). If the feed rate is too high, the cutting edge may chip or shatter; if it is too low, the edge will "rub" against the workpiece surface rather than cutting, leading to rapid wear. The guiding principle is to maintain sufficient chip thickness per tooth-within the limits of the machine tool's rigidity-to ensure the cutting edge effectively "bites" into the material.
3. Cutting Depth
The axial depth of cut (ap) should generally not exceed 1.5 times the tool diameter, while the radial width of cut (ae) is recommended to be kept within 0.1–0.3 times the diameter. For micro-tools, using a shallow depth of cut combined with a high feed rate is the key strategy for extending tool life.
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Contact us:Company name:Kunshan Meiyaxing Hardware Machinery Co., Ltd;Tel:8618962438699;Address: Room 3003, Building 3, Zhengtailong, No. 1288 Chengbei Middle Road, Kunshan City, Jiangsu Province, China;Email:myxcuttingtools@gmail.com;Website: https://www.myxcuttingtools.com
