A corner radius end mill is a type of milling cutter featuring a rounded cutting edge instead of a sharp corner.
It combines the durability of a bull nose end mill with the precision of a flat end mill.
This tool is widely used in CNC machining to reduce chipping, extend tool life, and improve surface finish.
It is particularly suitable for machining steel, stainless steel, aluminum, titanium, and other tough materials.
Using a corner radius end mill provides multiple advantages.
The rounded corner reduces tool breakage and wear, especially in high-speed machining.
It enhances chip evacuation and minimizes stress concentration in the cutting zone.
This results in smoother finishes, longer tool life, and improved dimensional accuracy.
It is an excellent choice for both roughing and finishing operations in precision milling.
Corner radius end mills are versatile and can be used for a variety of materials.
Common applications include machining hardened steel, alloy steel, stainless steel, aluminum alloys, copper, brass, and plastics.
The selection of coating, such as TiAlN, TiCN, or AlTiN, can further improve performance when machining specific materials.
While both have a rounded cutting profile, their geometry serves different purposes.
A ball nose end mill has a full radius for 3D contouring and sculpting complex surfaces.
A corner radius end mill has only a partial radius at the edge, making it better for slotting, profiling, and finishing flat or angled surfaces.
The corner radius design provides stronger cutting edges and greater stability in milling operations.
Choose a corner radius end mill when you need a stronger cutting edge and reduced risk of chipping.
It is ideal for applications where the workpiece edges are prone to wear or when machining harder materials.
Compared to a square end mill, it produces a slightly filleted inside corner, which helps increase part strength and durability.
Key factors include the tool diameter, flute count, corner radius size, coating type, and material compatibility.
For high-speed CNC milling, a smaller radius may be preferred for detailed work, while a larger radius enhances tool life for heavy-duty cutting.
Choosing the right coating, such as TiAlN or DLC, can improve wear resistance and heat dissipation.
Popular coatings include TiAlN (Titanium Aluminum Nitride) for high-temperature resistance, TiCN (Titanium Carbonitride) for increased hardness, and AlTiN (Aluminum Titanium Nitride) for enhanced tool life.
For non-ferrous metals like aluminum or copper, DLC (Diamond-Like Carbon) or ZrN (Zirconium Nitride) coatings are effective.
The coating choice depends on your machining material, cutting speed, and coolant usage.
Use proper cutting parameters including optimal spindle speed, feed rate, and depth of cut.
Ensure correct tool holding and alignment to reduce vibration and chatter.
Apply suitable coolant or cutting fluid to prevent overheating.
Regular inspection and regrinding can restore cutting performance and reduce tooling costs.
Yes, corner radius end mills can be professionally resharpened to extend their service life.
The process involves regrinding the cutting edges and restoring the radius profile.
However, repeated sharpening will gradually reduce the tool diameter, which may affect dimensional accuracy in precision parts.
They are widely used in mold and die manufacturing, aerospace component machining, automotive parts production, and precision engineering.
Typical operations include slot milling, profile cutting, contouring, pocketing, and finishing of flat and angled surfaces.
The corner radius helps improve structural strength in the final product.
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