Do Variable Flute End Mills Make a Difference?

While milling machines are amazing tools, having to deal with tool chatter can be a not so amazing side effect of operating one. Tool chatter is a loud sound caused by tool vibrations. If you are sick of dealing with tool chatter then you have probably heard about variable flute end mills. These tools are specially designed to operate at high speeds while minimizing the effects of tool chatter. But are these tools all that they are cracked up to be?

The short answer is that yes, these tools can in fact help to significantly reduce internal tool vibrations and the screeching tool chatter that can accompany them. If that is all you needed to know, then you can stop reading right now and go pick some of these great cutting tools up for your milling machine. If you are interested in learning a little more about these tools and how they work, then read on.

Tool chatter is hard to avoid. All tools vibrate at high speeds. This is because of the fact that end mills are not perfectly rigid. They all have a little bit of flexibility to them that makes it possible for them to vibrate from side to side when they reach high rotational speeds. This sideward movement can be difficult to account for when designing a tool path. This means that while the tool is cutting, it is slamming from side to side against the face or faces of the workpiece that are being cut.

These countless tiny impacts come together to form the loud screeching sound that we know as tool chatter. So how can variable flute end mills help? It's simple, these tools are designed to be just a little asymmetrical. Asymmetry is the enemy of consistent oscillations. This means that if the tool is regularly experiencing different forces, it will be harder for it to build up the kind of dramatic internal vibrations necessary to cause tool chatter.

Because the asymmetry in these tools is only very slight, the internal forces at play become interesting to consider. A dramatically asymmetrical tool would pull itself apart from the effects of the different forces while cutting. Variable end mills are designed to be just asymmetrical enough to reduce the tool's ability to vibrate without sacrificing its integrity. This means that they will offer the same long lifespan as other tools while operating at a fraction of the volume.

If you are tired of tool chatter and are interested in finding some variable flute end mills for your shop, then it is important to buy from a quality manufacturer. Online Carbide is an American manufacturer of solid carbide end mills and drill bits. These tools are able to handle incredible amounts of strain, easily outperforming similar steel tools. Their variable end mills are specially designed to reduce tool chatter and ensure a great finish on your workpiece. You can see all of the tools that they have available when you visit www.onlinecarbide.com.

Posted September 28, 2021 06:09

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Understanding Variable Helix and Variable Flute End Mills

When it comes to milling components, speed is the name of the game. High speed tools can help you get your work done faster, but running at high speeds and feeds does come with certain risks. Some tools just cannot stand up to the heat and strain experienced at high speeds, while others may not be stable at such high rotational speeds. Today we will be looking at two types of end mills that are designed to deal with high speed chatter, variable helix and variable flute end mills.

Chatter is one of the most annoying issues when it comes to milling. When tools reach high speeds, they begin to wobble. This movement is almost imperceptible, but it can have big impacts. As a tool wobbles, it begins to strike against the workpiece, causing increased friction and a loud sound. Because this is happening dozens of times per second, those tiny impacts can compound into the ear splitting phenomena known as tool chatter. This is not only annoying for the operator, but the vibrations can also affect the finish on your workpiece.

Variable end mills are designed to help machinists deal with tool vibrations and side effects like chatter. The whole idea behind these end mills is to create intentional asymmetry. While an asymmetrical tool design may seem like a bad idea, it can really help to minimize vibrations. Tool vibrations are caused by regular forces and irregular forces can help cancel out strong vibrations and increase stability.

Variable helix end mills use flutes with slightly different helix angles. The helix angle changes from flute to flute, but is consistent along the length of each flute. This helps to alter the distance between each flute striking the workpiece while maintaining an even flute spacing at the base of the cutting tool.

In addition to variable helix cutters, there are also variable flute end mills. When you imagine 4 flute cutting tools, it seems intuitive to separate each flute by 90 degrees from the next. Variable flute/pitch tools have slightly different angles between each flute. This difference may only be a degree or so away from a perfect 90 degree angle, but it can help to break up the timing between cuts, interrupting harmonic vibrations just like a variable helix cutter.

If you are interested in cutting down the tool chatter, then variable helix and variable flute end mills may be the perfect solution. You can find great deals on American made solid carbide variable end mills when you visit www.onlinecarbide.com. All of their tools, including their variable helix options, are machined to precise tolerances from high quality tungsten carbide tool stock. Their tools are also always available at manufacturer direct pricing, which can help you save big on the drill bits and end mills that your shop needs. If you have any questions about any of the products they carry, you can reach out to a member of their team by sending and email to sales@onlinecarbide.com.

Posted April 1, 2021 03:53

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