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What is the difference between flat head, ball head and round nose milling cutter?

In the application of high-speed machining, the flat blade is too fast to feed and the feed rate is too fast, so it is not suitable for high-speed machining. Ball knives are quite frequent in current high-speed machining, but in some respects it does not apply. When you use a ball knife, the cutting line speed will change from point to point. Tool life will also be greatly buckled, but the ball cutter is suitable for processing residual materials. The round nose knife itself is most suitable for high-speed machining, because it has the characteristics of corners that are not easy to crack and the stability of cutting line speed, which is unmatched by flat and all knives.

1. The ball cutter is generally an one-piece structure. The size of the new cutter is precise, and some narrow recessed areas are used. However, no matter how high the speed is, the center point of the ball cutter is always stationary. When the part comes in contact with the workpiece, it is not milling, but grinding. This is the reason why we often see that the tip of the ball cutter is particularly prone to wear. We will also find that the more definite areas, the better the finish with a ball cutter.

2, round nose knife, generally inlaid structure, each time the blade is replaced will make the tool size change slightly, there is no static cutting edge, the blade wear is also small, the knife spacing can also be increased. However, due to the dead zone in the front end of the tool, a “top knife” phenomenon may occur in some constricted recessed areas. In addition, since the automatic clearing function of the current machining is based on the ball cutter, even if the reference tool you set is a round nose knife, in the actual calculation process, the ball cutter of the same diameter is always used for reference. If you use automatic corner cleaning directly, it will not be covered in some recessed areas.

Therefore, it is necessary in order to select a suitable tool according to the specific workpiece shape. If the workpiece is large, the surface changes little, there are fewer narrow recessed areas, and there are more relatively flat areas. It is strongly recommended to use a rounded nose knife to process, and then use the secondary roughing method to find the area that needs subsequent processing. If the workpiece is small, the surface changes greatly, and there are many narrow recessed areas, you can still use a ball cutter.

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