MITGI End Mills

FAQs

• How do you decide whether to use a standard tool or move to a custom?

  There are several answers to this seemingly simple question. For example:

  • Lead time may be a deciding factor. Our regular lead times for standard tools is 3 days or less, while custom tools are usually available in 2 weeks or less. Regardless of how we quote a tool in normal circumstances, we understand when companies are pressed for time. We don’t charge to expedite, but we will try to accommodate schedules whenever possible. Let us know what you need and we’ll do our best to achieve it.
  • Production volume may drive your decision. If you are a high-mix, low-volume facility, a standard tool may be a great option for you. A MITGI standard tool will help achieve tight tolerances and great surface finish and can be used in a variety of materials and projects. If you are a high-volume, low-mix facility, custom tools may be worth considering. When production lines are tasked with increasing tool life, improving cycle times, or increasing throughput, custom tools may help to achieve the goals through application-specific features and geometries.
  • Not sure? Just ask. Send us your tool specs, info on the project, and any goals you’re trying to achieve. If a standard tool exists, we’ll let you know. If we see any opportunities for improved performance by moving to a custom, we’ll give you the option to consider. 

• How can surface finish be improved when using an end mill?

  Many factors could impact the final surface finish of a product. To start, it’s good to check the basics: Is the tool secure in its holder? If you adjust the speeds and feeds, does the surface finish improve? What does the surface look like before this tool engages? Are there any changes in the application that could impact the surface finish (different material, different material lot, different equipment, change in programming)? Once you’ve considered all of those options and ruled out potential contributing factors, it’s time to turn to the cutting tool. To assess the situation, we welcome as much info as you can give us. Understanding how the tool is being used and what you’re seeing will help guide us toward the options that are most likely to improve the finish. For example, we may recommend a change to the cutting action (honed edge, sharper cutting edge), additional rigidity (thicker core, larger shank diameter), or a way to alleviate chips (more/less flutes, coolant thru, chip breakers).

• What are the factors to consider that determine flute count?

  One of the key factors is the material that the tool will cut. A general rule of thumb is that a lower flute count is good for softer materials, leaving ample room for the long strings of chips that soft materials may produce. A higher flute count is good for harder materials, allowing more frequent points of contact to help keep the tool engaged in the hard surface. It’s important to remember that many factors impact tool performance and flute count is only one of them.

• What kind of geometry options are used on end mills?

  To determine the best end mill geometry, we’ll want to know a few key things:

  1. What material are you cutting?
  2. What operations will it do?
  3. Is it a new tool replacing one already in use?

  Material: The material that an end mill is cutting helps to determine some of the primary geometry design decisions. For softer materials, a very sharp edge is needed to shear the material, but for harder materials, a honed edge may make the tool less grabby. The material may also tell us what kind of helix angle would give the best chip evacuation. 

  Operation: Understanding how the tool will be used helps to define geometry features that will best help support it. For example, if an end mill is side milling or plunging a thicker core may help to provide extra rigidity. For profiling, a ball end finish will provide the best results. Knowing the depth of cut will ensure that the tool design includes the flute length required, while including only what’s needed to help prevent unnecessary costs.

  New or Replacement: If you’re already using an end mill, but it’s not giving the results you need, understanding what you’re using can give us valuable clues. With micro tools, small geometry changes may change the tool’s performance dramatically. While the final tool design may be a departure from the original, it still gives us important information.

• How can you extend the life of an end mill?

  If your end mill is working well, but you’d like it to last longer, the coating is often a good place to start. It may not be suitable for every material, but the added lubricity and heat control that the coating provides may help to extend tool life. If your tool is already coated, it may be worth considering switching to a different coating. There may be more than one coating that is suitable for a material, and upgrading to a higher-performance coating may help extend life in applications that produce more heat. Learn more about our in-house coating options.

  Assessing the wear on an existing tool may point directly to tool changes that may contribute to premature wear. Sometimes the wear patterns may be visible, but it may require examination under magnification. Contact us to discuss options.