Short Answer:

Milling cutters are the cutting tools used in milling machines to remove material from the workpiece surface. They come in various shapes and sizes depending on the type of milling operation to be performed. Common types of milling cutters include plain milling cutters, end mills, face mills, side and face cutters, and form cutters.

Each type of milling cutter is designed for a specific operation such as producing flat surfaces, cutting slots, making grooves, or shaping complex profiles. The choice of cutter depends on the workpiece material, type of surface required, and desired accuracy of machining.

Detailed Explanation :

Types of Milling Cutters

Milling cutters are essential tools used in milling machines to perform various metal cutting operations. These cutters have multiple cutting edges, which remove material from the workpiece as they rotate at high speed. The design, size, and shape of milling cutters vary according to the type of operation being performed. They can be made from high-speed steel (HSS), carbide, or other hard materials to ensure durability and cutting efficiency.

The main function of a milling cutter is to produce precise shapes, smooth finishes, and accurate dimensions on the surface of a workpiece. Different types of milling cutters are used for specific operations such as face milling, end milling, slot milling, and form milling. Below are the major types of milling cutters used in machining work.

1. Plain Milling Cutter

Plain milling cutters are the most common type used for cutting flat surfaces parallel to the axis of rotation. They have straight or helical teeth on the periphery of the cutter. These cutters are generally used in horizontal milling machines for heavy-duty cutting operations. Helical teeth cutters are preferred for smooth cutting and better chip removal.

2. Face Milling Cutter

Face milling cutters are designed to produce flat surfaces on the face of the workpiece. The cutter has teeth on both its face and periphery. The cutting action occurs mainly at the face of the cutter, making it suitable for large flat surfaces. Face milling is commonly used in vertical milling machines and provides a good surface finish.

3. Side and Face Cutter

This type of cutter has teeth on both the periphery and sides. It is used to cut slots and grooves or for machining the sides of a workpiece. The side and face cutter allows cutting on both sides at the same time, which helps to increase machining efficiency and reduce time.

4. End Mill Cutter

End mills are widely used in vertical milling machines for profile cutting, slotting, and contouring. They have cutting teeth on the end as well as on the sides. End mills are available in different shapes such as flat-end, ball-nose, and corner-radius types. They are mainly used for machining complex surfaces and parts requiring precision.

5. Form Milling Cutter

Form milling cutters are specially designed for machining complex profiles like grooves, threads, or gear teeth. The shape of the cutter corresponds to the contour of the surface to be machined. These cutters are used for repetitive production where the same shape or form needs to be cut multiple times with accuracy.

6. T-Slot Cutter

A T-slot cutter is used to machine T-shaped grooves on a workpiece. It has a narrow neck and a wider cutting head that enables it to form the undercut portion of a T-slot. T-slot cutters are essential in making work-holding devices like clamps and fixtures.

7. Metal Slitting Saw Cutter

These cutters are thin circular cutters used for cutting narrow slots or for parting-off operations. They are available in different thicknesses and diameters. Metal slitting saw cutters can perform precise cuts and are often used for cutting small metal pieces or for slotting keyways.

8. Angular Milling Cutter

Angular milling cutters have their cutting edges set at an angle other than 90° to the cutter axis. They are used to produce angular grooves or chamfers on the workpiece. Common types include single-angle and double-angle milling cutters. The single-angle cutter has teeth on one side, while the double-angle cutter has teeth on both sides.

9. Fly Cutter

A fly cutter consists of a single-point cutting tool held in a rotating arbor. It is used to machine large flat surfaces with good surface finish. Fly cutters are often used in tool rooms and for light-duty milling operations because they are simple and easy to use.

10. Gear Cutter

Gear cutters are specially designed for machining gear teeth. They come in different forms depending on the type of gear being manufactured, such as spur gear, helical gear, or bevel gear cutters. Gear cutters ensure high accuracy and proper tooth profile formation.

11. Woodruff Keyseat Cutter

These are small disc-type cutters used to cut keyseats or slots for Woodruff keys. The cutter is mounted on an arbor and used for precise machining of keyseats on shafts. They are often used in the manufacturing of mechanical components requiring key and slot connections.

12. Flywheel Cutter

Flywheel cutters are used in heavy machining operations, especially for finishing flywheel surfaces or for large circular components. They provide a good surface finish and are mainly used in automotive and industrial workshops.

13. Thread Milling Cutter

Thread milling cutters are used to cut threads on a workpiece by using a helical cutting motion. Unlike a tap, which cuts threads in a single pass, thread milling provides more control and produces precise threads with better surface finish.

Conclusion

Milling cutters play a vital role in machining operations by shaping and finishing metal surfaces with high precision. Each type of milling cutter has a specific function depending on the nature of the work and the desired outcome. From basic plain cutters to complex form and thread milling cutters, their design and selection depend on the machining requirements. The correct choice of cutter not only ensures efficient operation but also improves surface finish, tool life, and production quality in manufacturing industries.