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Ball end mills, also known as ball nose cutters or R cutters, are tools with a blade similar to a ball end, mounted on milling machines specifically for milling curved surfaces or arc-shaped grooves.
Ball nose cutters, generally of an integral structure, have blades that are not easily chipped and exhibit excellent milling performance when processing curved surfaces. They can also process small concave areas. The main difference between a ball nose cutter and a round nose cutter is that, regardless of the rotation speed, the center point of the ball nose cutter remains stationary. The center part does not mill the workpiece but rather grinds it. Therefore, the tip of the ball nose cutter wears out more easily. Additionally, due to the blade characteristics, the processing surface tends to be rougher when working on relatively flat workpieces, making ball nose cutters less suitable for milling flat workpieces.
Ball end mills can mill mold steel, cast iron, carbon steel, alloy steel, tool steel, and general iron materials. They can also perform profile milling on high hardness materials up to 70 HR, including alloy steel, nickel-based alloy, and titanium alloy.
Ball nose cutters are widely used for various curved surfaces, arc-shaped groove processing, and are also competent in processing complex surfaces. They are mainly applied in mold and turbine manufacturing, the aircraft industry, and other sectors.
Suitable for dry, high-speed cutting.
Allows for flexible changes in processing angles.
Excellent surface roughness, very high milling efficiency.
Supports high-speed and high-feed milling in back milling mode.
The highest temperature for maintaining cutting performance is between 450-550/500-600 degrees Celsius.
When machining with a ball nose cutter, the entry angle changes continuously with practically no sudden changes, making the change in cutting force a continuous process. This ensures a more stable cutting state and higher surface finish when processing.
Minimal residual material is left after semi-finish machining, which is advantageous for subsequent finish machining. The path spacing for semi-finish machining is generally twice that of finish machining. If the parallel sectioning method is used, it is best to place it at a 90-degree angle with the finish machining feed direction.
Using a ball nose cutter reduces the effective cutting diameter, lowering the cutting line speed, cutting power, and cutting torque, making the processing more efficient.
Characteristics: This type of ball end mill has only one cutting edge, typically used for softer material processing, suitable for high cutting speeds and rapid feed rates.
Characteristics: The double-flute design allows the ball end mill to share the workload during cutting, suitable for most conventional metal processing.
Characteristics: Four-flute ball end mills have more cutting edges, resulting in higher cutting power and better stability.
Characteristics: Made of carbide materials, these ball end mills possess extremely high hardness and wear resistance, suitable for high-speed cutting and hard material processing.
Characteristics: Coated ball end mills typically have a special hard coating (such as TiN, TiAlN, etc.) applied to the tool surface to enhance wear resistance, corrosion resistance, and high-temperature performance.
Characteristics: These ball end mills have smaller diameters and are usually used for micromachining and precision part milling.
Characteristics: Long-neck ball end mills have longer shanks, suitable for deep hole or narrow space part processing.
Characteristics: This type of ball end mill can be used on both ends, allowing workers to replace the tool when it wears, thus extending the tool's lifespan.
