Choosing the right end mill for your DIY project or any other drilling job can be an intricate task. This is because there are a number of variables that come into play when you ultimately choose an end mill.

Are you making straight cuts or contoured cuts? What materials are you using in your project? How deep do you need to penetrate into the material? How many flutes do you need or what kind of machining operations do you need to perform?

This article focuses on three things to know before choosing end mills for DIY.

What type of material do you want to use?

So, does your DIY project involve plastic, aluminium, plywood, hardwood, ferrous materials or any other harder surface like concrete or bricks?

Each material has a specific property and needs a specific end mill. For instance, if you are working with hardwood, you need to go for an end mill with a clean edge.  If your DIY project involves non-ferrous materials, the best option is an end-mill with not more than 2 or 3 flutes. You would need a larger number of flutes for more productivity in shorter chipping materials such as high carbon steel and iron.

What kind of application are you performing?

Some of the common DIY machining operations are finishing, contouring, semi-finishing and finishing, traditional roughing, slotting, and face milling, among others. Once you know what kind of application you need to perform, it is easier to choose the end mill you need.

For example, for a DIY job that needs traditional roughing, go for an end mill with lesser flutes.

What kind of end mill coating should I pick?

End mills are coated with chemical coatings to reduce wear and friction. You have to keep in mind that not all end mill coatings are appropriate for all materials and applications. A particular coating may be good for productivity on one material but may not be suitable on another.

For instance, though an Aluminium Titanium Nitride (AlTiN) coating increases hardness and temperature resistance in ferrous materials, it can cause a high affinity to aluminium, causing work piece adhesion to the cutting tool.

Common mistakes you need to avoid while choosing end mills

  • Running your machine too fast or too slow can run the risk of recutting chips and accelerating tool wear.
  • Choosing the wrong flute count can cause wear on the end mill and you need to be careful to not overload it.
  • Picking the right end geometry is critical.
  • Your end mill should have the correct dimensions for the DIY job you need to perform. Some of the dimensions you need to take into account include cutter diameter, length of cuts, reach, and profile.

Different types of end mills

End mills are divided based on a number of factors.

  • Number of flutes: single flutes, two flutes, three flutes, and multiple flutes.
  • End-cut type: centre cutting end mills, and non-centre cutting end mills.
  • Shank type: plain shanks and Weldon shanks.
  • Coatings: Titanium Nitride (TiN), Titanium Carbonitride (TiCN), Titanium Aluminium Nitride (TiAlN), and uncoated end mills.
  • Cutting tool material: High Speed Steel (HSS), Solid Carbide, and Vanadium High Speed Steel (HSSE).

If you need end mills for any of your DIY projects, take a look at our extensive selection of products available in different cut lengths and diameters, materials, shank types and diameters, surface finish etc., on our website.