Face milling is the most common milling operation and can be performed using a wide range of different metal cutting tools. Face Milling Cutters with a 45º entering angle are most frequently used, but round insert cutter, square shoulder cutters and side and face mills are also used for certain conditions.

45° cutter

• First choice for general purpose
• Reduce vibrations on long overhangs
• Chip thinning effect allows increased productivity

90° cutter

• Thin walled components
• Weak-fixtured components
• Where 90° form is required

Round insert cutter

• General purpose cutter
• Strongest cutting edge
• Many edges per insert
• Especially suitable for heat-resistant alloys, ISO S.
• Smooth metal cutting action

Roll into cut

• Consider machine tool stability, spindle size and type (vertical or horizontal) and available power.
• Use a cutter diameter that is 20 to 50% larger than the workpiece.
• Consider maximum chip thickness when positioning the cutter for optimum feed.
• Position the cutter off centre to produce the thinnest chip at exit.
• Apply down-milling for favourable chip formation, i.e. thick to thin chip.
• Program the cutter to roll into the cut and reduce the feed to obtain a smooth entry.

Keep cutter constantly engaged

• Apply down-milling for favourable chip formation, i.e. thick to thin chip.
• Avoid entries and exits through tool path programming.

Frequent entering and exiting the workpiece should be avoided if possible. It can create unfavorable stresses on the cutting edge, or cause dwell and chatter tendencies. It is recommended that you program a tool path that keeps the milling cutter in full contact, rather than performing several parallel passes. When changing direction, include a small radial tool path to keep the cutter moving and constantly engaged.