Now we will study in detail the various cutters according to shapes (Various types of milling cutters are shown in Fig. 16.36 to 16.48).

Type # 1. Plain Milling Cutter:

It has straight or helical teeth cut on the periphery of a disc or a cylindrical surface. It may be of solid inserted blade or tipped type, and is usually profile sharpened but may be form relieved also. Generally helical teeth are used if the width of the cutter exceeds 15 mm.

Slot Milling (169) Slot Side (169) Slot Square End. Insert Thickness S Insert Thickness W Insert Width. Cutting Edges per Insert. Also known as Woodruff keyseat cutters, these tools mill precise notches in rotary shafts and can also be used for slot milling. Dovetail End Mills Create dovetail slots for joining components, holding work, or housing an O-ring or other seal. MSC offers a complete selection of angle, radius, side, T-slot cutters and more to tackle all your machining jobs. We also carry a full range of shell end mills in high-speed steel, cobalt and powder coated metal to match your needs. When accuracy and precision are the tasks at hand, MSC has the milling machine tools your work demands. Milling is a cutting process where we use a cutter to remove the material from the surface of a metal or work piece. This cutter which we use has multiple rotating cutting surfaces. Milling cutters play an important role in the milling process and they are used in several milling machines. MSC offers a complete selection of angle, radius, side, T-slot cutters and more to tackle all your machining jobs. We also carry a full range of shell end mills in high-speed steel, cobalt.

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The plain milling cutter is generally used for milling flat surfaces parallel to cutter axis. Helical teeth cutter is used where large stock removal is required. Helical angle permits several teeth to cut simultaneously which results in smoother cutting action.

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Heavy duty plain cutters have fewer teeth and helix angle of 35-45°. These are sometimes nicked on their periphery on a helical pattern for chip breaking and smooth operation.

Type # 2. Side Milling Cutter:

This cutter is similar to plain cutter except that it has teeth on the side. However, the side milling cutter may have teeth on the periphery and on one or both sides of the tool. These cutters may have straight, spiral or staggered teeth. Further these may be solid, inserted blade or tipped construction, and may be profile sharpened or form relieved.

Half side milling cutters have teeth only on one side in addition to circumferential teeth. These cutters are usually used in pair for milling both ends of work to a given dimension.

Type # 3. End Mill Cutters:

These cutters have an integral shaft for driving and have teeth on both periphery and ends. These are the cutters with teeth on the periphery and end integral with a shank for holding and driving (Refer Fig. 16.41). These are used to mill flat, horizontal, vertical, bevel, chamfer and slant surfaces, grooves and keyways, and to cut slot and in recess work such as die making etc.

The flutes on the cutter may be either straight or helical. End mills with high helix are used for milling aluminum and light metals. The end mill cutter may have either taper shank (tanged or tapped) or straight shank.

Large cutters (shell end mill cutters) have the cutter part separate and are held to a stub arbor owing to the high cost of the high speed steel. This construction results in a considerable saving in material cost.

Type # 4. Metal Slitting Saw Cutters:

Indexable Slot Milling Cutters

These cutters resemble a plain to side cutter except that these are made very thin. These are usually profile sharpened and may be either solid or tipped. These are used for cutting off and slotting operations and are somewhat similar to the circular saw blades. Plain cutters of this type are relieved by grinding the sides to afford clearance for the cutter.

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Generally there are six types of saw cutters:

(a) Plain Metal-Slitting Cutters:

These are used for fine slitting operation and have teeth of saw-tooth form with both sides slightly concave to provide clearance while cutting.

(b) Staggered-Teeth Milling Cutters:

These are similar to the staggered teeth side milling cutters and have their teeth staggered at the periphery with alternate right-hand and left hand helix angles and are made in relatively narrow widths.

(c) Side Teeth Slitting Cutters:

There are suitable for cutting off wider material or for making a deep slot.

(d) Angle Milling Cutters:

Any cutter, angle shaped, comes under this classification. These may have cutters either on only one conical surface (single-angle cutter) or on two conical surfaces (double angle cutter). Angle cutters are used for cutting ratchet wheel, dovetails, flutes on milling cutters and reamers, machining angles and V_s of 30°, 45°, 60° and 90°.

Angle milling cutters have circumferential teeth and its cutting edges lie on a conical surface (Refer Fig. 16.43).

(e) Concave Milling Cutter:

This is a formed cutter which is shaped to mill a convex surface of circular contour equal to half a circle or less (Refer Fig. 16.44).

Milling Machine Cutter Sets

(f) Cylindrical Milling Cutter:

This is the cutter having cylindrical shape and teeth on the circumferential surface only (Refer Fig. 16.45).

Type # 5. T-Slot Cutters:

These are used for milling T-slots in one operation and are available in special sizes for standard T-slots. These resemble plain or side milling cutters which have an integral straight or tapered shaft for driving.

Straight or staggered teeth are cut on the periphery and both sides. For making T-slot, first a side milling cutter makes the groove and then the T-slot cutter enlarges the width of the bottom of the groove of form the desired T-slot.

Type # 6. Form Milling Cutters:

These have a special curved tooth outline and are used for milling contours of the various shapes. According to the method of gr

Milling Machine Slot Cutter Thicknesses