With the versatility and efficiency of milling cutters, they have become a preferred option for many modern cutting processes. The complexities of designing and manufacturing milling cutter materials, shapes, and structures are immense. However, among the wide range of milling cutters available, there are distinct differences between flat end mills and keyway mills.
Flat end mills are commonly used in milling operations and are easily recognizable by their flat or square-shaped cutting edge. They are versatile in their application and can be used for creating flat and angled surfaces. This makes them ideal for shaping materials like wood, plastics, and metals. Their popularity can be attributed to their ability to provide smooth finishes and precision cuts.
On the other hand, keyway mills are designed for specific cutting tasks, like creating keyways and slots in materials. Keyways are critical features in machinery components that provide a secure fit between two parts. Keyway mills have cutting edges that are shaped to create these features accurately and efficiently. Unlike flat end mills, they are not as versatile in their application and are less useful for creating various shapes and surfaces.
In conclusion, while milling cutters have revolutionized the cutting process, the differences between flat end mills and keyway mills cannot be ignored. Flat end mills are versatile and ideal for shaping materials, while keyway mills are specific and designed for creating keyways and slots in machinery components. Understanding these differences can help you choose the right milling cutter for your project.
one. different shape
Keyway mills and flat end mills may appear similar, but they possess distinct characteristics.
An end milling cutter with a flat shape has a relatively loose outer diameter and features helical teeth.
The keyway milling cutter is designed with a small helix angle, a shallow groove depth, and a straight-line back that closely resembles that of a twist drill. Its construction comprises only two cutter teeth, and the cutting edge of the end face extends to the center, much like the flat end milling cutter and drill bit.
two. different performance
When comparing flat end mills and keyway mills, the most significant difference lies in their respective performances. While both tools are commonly used in machining, the flat end mill is primarily used for shaping and smoothing surfaces, whereas the keyway mill is designed specifically for forming keyways or slots in a workpiece. The cutting edges of a flat end mill are evenly spaced along the circumference of the tool, allowing for a smooth and consistent cut. In contrast, the keyway mill features a narrower cutting edge that is specifically designed to create precise keyways of varying widths and depths. Ultimately, the choice between these two types of end mills will depend on the specific application and desired outcome of the machining process.
1. The number of teeth is different
The type of machining the tool is used for is determined by the different number of teeth on the cutter. By rearranging the content, we can say that the machining application of the tool is dependent on the number of teeth present on the cutter.
The flat end milling cutter is designed with various tooth configurations, including single teeth, two teeth, four teeth, and more, providing versatility in cutting options. It excels in smoothly cutting the side edges with high efficiency. The outer diameter of the cutter is typically larger, allowing it to be ideal for surface machining applications.
To minimize the impact of the radial cutting force, keyway milling cutters are designed with two symmetrical cutter teeth. This design allows the radial forces generated by each cutter tooth to cancel each other out during operation, enabling the machining of a keyway in one go with the same width as the rotational diameter. Compared to flat end milling cutters, keyway milling cutters offer a higher cutting volume.
2. With or without center hole
The ability of the milling cutter to move vertically downwards depends on the location of its center. This means that if the center is not properly positioned, the cutter may not be able to make straight feed. To achieve precise and accurate milling operations, it is crucial that the center of the cutter is correctly placed.
The flat end milling cutter is designed with a center hole on its end face. However, it is important to note that this cutter cannot be fed directly downwards. If the cutter is fed too deeply, the central hole will bear the weight, preventing further feed and making it unsuitable for cutting keyways. Therefore, it is important to use the flat end milling cutter with care and precision to ensure that it performs optimally.
A keyway milling cutter is a tool used for cutting grooves and keyways in a variety of materials. Unlike other milling cutters, it features an end face that does not have a center hole. This design allows it to feed directly downwards, much like a drill bit. As a result, it is perfect for making flat-bottomed holes.
When it comes to milling grooves and keyways, a keyway milling cutter is a go-to choice for many professionals. Its ability to drill precise, flat-bottomed holes makes it highly effective in a range of applications. Whether you are working with metal, wood, or another material, a keyway milling cutter is sure to deliver the results you need. So if you are looking to create intricate grooves or cut accurate keyways, this is the tool for you.
3. The number of margins is different
The number of lands plays a significant role in determining the overall quality and accuracy of machined holes. It affects several factors such as the surface finish, straightness, and roundness, which are crucial for achieving the desired results. Therefore, it is essential to consider the number of lands during the machining process to ensure maximum precision and efficiency.
The flat-end milling cutter boasts multiple margins, and as its diameter increases, so does the number of margins. This feature allows for greater work efficiency, making the cutter an essential tool for any milling job.
The keyway milling cutter usually has only two flutes that are primarily designed for axial movements, similar to that of a drill. As a result, this cutting tool is highly efficient when it comes to cutting keyways. However, its design is not suited for generating complex shapes or profiles. Its simplicity in design and function makes it an excellent choice for simple cutting tasks.
4. Different outer diameters
The quality of the keyway and key are directly impacted by the difference in outer diameter. As a result, there will be a need for stricter tolerances to ensure that the final product meets the required specifications. It is crucial to pay close attention to the outer diameter to guarantee the precision of the key and keyway. Any deviation from the specified tolerances could result in poor performance or even failure of the final product. Therefore, it is vital to ensure that every aspect of the manufacturing process is carefully controlled and monitored to produce the best possible results.
The flat end milling cutter is designed with a slightly loose outer diameter, which results in improved chip removal. This characteristic makes it particularly suitable for effectively machining various surfaces.
To ensure a tight fit of the key after installation, the size requirements for the keyway machining are relatively high. As a result, the outer diameter of the keyway milling cutter must be precise. This is essential in achieving the desired precision and accuracy in the milling process. Only then can the required level of quality be achieved in the final product. Therefore, it is crucial to use a keyway milling cutter with a high level of precision to avoid the risk of a loose key.
three. different uses
Flat end mills are versatile cutting tools that are commonly used for various milling operations such as face milling, groove milling, step face milling and milling. These tools are essential to many machining processes and can be used on a variety of materials. They are typically made from high-speed steel or carbide, with different coatings available to improve tool life and performance. Whether you are milling a prototype or producing high-volume parts, flat end mills are an essential tool for achieving accurate and efficient results. So, if you want to mill your way to success, make sure you have the right flat end mill for the job!
The keyway milling cutter is primarily utilized for the precise machining of keyways. To illustrate, one can employ a 6mm flat end mill along with a 6mm slot mill to effectively mill grooves. However, it should be noted that the 6mm flat end mill is more susceptible to breakage, while the 6mm keyway cutter effortlessly navigates through the process.