Face milling

Face milling is a method that allows for the processing of a planar surface on a workpiece. The milling cutter blades remove chips from the surface of the workpiece, and with this milling technique, precise dimensions and smooth surfaces can be achieved. Milling cutters are typically classified according to their rake angle, cutter shape, and intended use. These varying features have a significant impact on the result and efficiency of the milling process.

0–65° face mills

The largest group of cutters, particularly suitable for face milling. This group also includes cutters suitable for plunge milling with very small rake angles. These cutters are versatile and suitable for various types of machining tasks.

45° face mills

This type of milling cutter is one of the most common and is favored in general machining. The 45° rake angle allows for minimal vibration susceptibility and the formation of thin chips, which in turn enables good productivity. This cutter is particularly effective in long free cuts or with poorly supported workpieces.

90° mills

An excellent choice for thin-walled workpieces and situations needing weak clamping. A 90° mill is also the perfect tool for machining 90° corners, yielding a precise and clean result.

Round insert and large radius mills

Round insert mills are highly versatile and also suitable for demanding face milling. Their unique shape allows for oblique entry and they are particularly effective in contour milling.

In face milling, a very high feed per tooth can be achieved, up to 4 mm per tooth, when using small rake angles or round inserts. Optimized milling models have been developed for strategies of high feed and low axial cutting depth, known as high-feed mills.

Heavy face milling

For heavy face milling, such as the roughing of heavy forged or hot-rolled blanks and castings, robust and efficient milling machines are used. The management of very large chip volumes and high temperatures requires specially designed mills that can withstand heavy loads. The optimal rake angle for heavy face milling is 60°.

Wiper inserts

Achieving excellent surface roughness in face milling is possible by using wiper inserts, which work best with high feed rates per revolution and large-diameter mills. The unique shape of wiper inserts results in significantly better surface quality without the need to reduce feed rate.