End Mills (and Router Bits)
End mills are the cutting tools (also called router bits) that are inserted into the collet of a spindle
or router. It is the part that spins and does all of the cutting in all directions.
Some end mills can plunge into the material (like drilling). All end mills have
the ability to cut sideways (also called profiling).
Important Formulas:
Feedrate (IPM - Inches/Min) = Spindle RPM x # of Flutes x Chip Load
See each end mill for the chip load value.
If your machine cannot achieve these feed rates, reduce the spindle RPM using this formula:
Speed (RPM) = Feed Rate (IPM) / (# of Flutes x Chip Load)
Compression End Mills
If you want a good quality cut along the top and bottom edge, the compression tool is what you will need.
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(60-113MW) Onsrud Compression End Mill - Cut Length - 7/8 inch or 22.225mm
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Bottom Clearing (Surfacing) End Mills
These end mills will create a flat surface. Generally, these end mills are great
for surfacing your spoil board on your CNC machine, but can be used to surface for
other purposes as well.
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Onsrud Spoilboard Surfacing Cutter
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Single Flute End Mills:
My personal favorate when cutting plastic or for quiet wood cutting. The cutting
speeds can be increased when using these end mills since the chip load cavity is
larger than the standard two flute end mills. Upcut end mills (router bits) will leave
good finish to the bottom edge of the material but can lift thin or light material since
the geometry is designed to cut in the upward direction. If thin or light material
must be cut and you want a good top edge finish, consider downcut end mills
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(65-000) Onsrud Single Flute: 1/16" Cut Diameter, 1/4" Cut Length, 1/8" Shank
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1/4" x 1-1/4" Solid Carbide One Flute Downcut Super O Flute for Plastic, Wood, Aluminum
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Shank and Cut Diameter 1/4" (6.35mm) Cut Length: 1/2" (13mm)
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(65-012) Onsrud Single Flute: 1/8" Cut Diameter, 1/2" (13mm), Cut Length, 1/4" Shank
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(65-026) Onsrud Super 'O' Cut and Shank Diameter: 1/4" (6.35mm) Cut length: 1-1/4" (31.75mm)
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Two Flute End Mills (General Purpose):
These end mills are the workhorses and will generally cut most materials, but keep
an eye on the feedrate.
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1 1/2" Carbide Tipped Two Flute Straight 90° V Flute for V-Grooving or Beveling Edges for Wood
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1" Carbide Tipped Two Flute Straight 60° V Flute for V-Grooving or Beveling Edges for Wood
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2" Carbide Tipped Two Flute Straight 120° V Flute for V-Grooving or Beveling Edges for Wood
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2" Carbide Tipped Two Flute Straight 140° V Flute for V-Grooving or Beveling Edges for Wood
General Purpose End Mill: Cut Length 1-1/8", 1/4" DiameterCut deeply into wood with this extra long length of 1-1/8". Features include, solid carbide (micro grain), 2 flutes, right hand rotation (up cut), overall length of 3", 1/4" shank diameter and 1/4" cut diameter, and a 30 degree helix.
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1/4" 2 Flute Straight V Flute End Mill
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Onsrud 1/4" diameter 1" cut length end mill (Extended Shank Length) Overall Length: 4"
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Onsrud Upcut Foam End Mill Cut Diameter: 1/4" Cut Length 2-1/4" Shank 1/4"
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Onsrud 1/8" (Extended Length) End Mill. Shank: 1/4", Cut Length: 1/2", Overall Length: 3"
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Chipbreaker/Finisher Down Cut 1/2" Cut Diameter, 1/2" Shank, 1-5/8" Cut Length, 3-1/2" Overall Length
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Chipbreaker/Finisher Down Cut 3/8" Cut Diameter, 3/8" Shank, 1-1/8" Cut Length, 3" Overall Length
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Chipbreaker/Finisher Up Cut 1/2" Cut Diameter, 1/2" Shank Diameter, 1-5/8" Cut Length
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PCB Isolation and Etching End Mills:
These are etching and engraving bits that can be used with non-ferrous metals, hardwoods,
phenolics, stabilized woods and composite materials.
3D Carving Tools:
For all types of applications including: dimensional signage, 3D carving, 3D contouring
and profiling, cabinetry and furniture, and 3D millwork.
3D Carving End Mill with 1/16" TipSpecifications: 1/4" shank, 2" in total length, maximum of .0002" runout, solid sub-micrograin carbide. Oh yeah, the cut creates a really smooth edge or surface. These are available with or without ZrN coating for longer life.
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Tangential Dragknife Cutting Tools:
If you need to cut thin or flexible materials like vinyl, cardboard, paper,
mat board, or whatever yo would normally cut with a utility knife this is the
cutting tool for you. Just slip this tool into the collet of your spindle or
router and allow the drag knife to follow the direction and curves that your
CNC moves.
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Drag Knife - Tangential CNC Knife - D2 for 1/2" Collet
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A few important facts:
- Overall length or OAL is the total length of the end mill.
- Flutes are the portion of the end mill that does the cutting with sharp spiral or
non spiral edges. Flutes can be up-cut (brings the chips up and out of the cut)
or down-cut (forces the chips downward). Up-cut flutes will generally create a nice
edge finish on the bottom of the material. Down-cut will create a nice top edge
finish.
- Shank is the portion of the end mill that does not have flutes and is used as the
area for collet contact.
- Most of the measurements will be shank diameter and flute diameter and flute length.
Shank diameter is important in that you will need the correct collet to receive
the shank. FLute diameter will create the width of the cut, or hole size.