2024/10/04 004｜Application and development of ball End Mill (Part 1)

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Application and development of ball End Mill (Part 1)

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1. Introduction

Ball milling cutter is a cutting tool with a hemispherical blade. It is widely used in precision processing operations such as curved surface processing, arc grooves, grinding and polishing of various materials. Its unique geometric shape can achieve high precision and high precision. Surface processing effects such as smoothness and high degree of completion make ball milling cutters particularly suitable for processing three-dimensional curved surfaces and complex shapes, especially "curved surface processing" is more representative!

Although ball milling cutters are suitable for processing curved surfaces, it does not mean that they cannot process flat surfaces. They can still form flat surfaces through tool paths or unique technologies. In addition, ball milling cutters have a wide range of applications, such as precision molds and curved surface design. , 3C parts, medical equipment parts, aerospace parts, automobile and motorcycle parts, daily necessities parts, etc. The flexible use and superior cutting effect of ball milling cutters have made it a reliable choice for the processing needs of industrial and precision industries. solution.
 

2. History

The development of ball milling cutters can be traced back to the early 20th century. With the advancement of mechanical processing technology, the demand for high-precision curved surface processing and complex shapes has gradually increased the use of ball milling cutters. The earliest ball milling cutters Mainly used for wood processing, and then gradually used in the field of metal processing. With the advancement of material technology and manufacturing technology, the efficiency and application breadth are continuously improved. Modern ball milling cutters can already handle high-strength and high-hardness materials, and have Longer service life and higher processing efficiency.
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3. Characteristics of ball End Mill

➤ Hemispherical blade design : This blade design is suitable for processing three-dimensional curved surfaces and difficult shapes.
➤ High-precision machining : Able to achieve very fine surface treatment and suitable for high-demand machining tasks.
➤ Multifunctional application : widely used in mold manufacturing, aerospace, automotive industry, medical equipment and other fields.
➤ Excellent surface finish : The surface is smooth after processing and can also reduce surface roughness and texture.
➤ Strong durability : Usually made of high-hardness materials, it has a long service life, and it is even better if it is coated.
➤ Strong adaptability : able to handle a variety of materials, such as metal, alloy, resin, plastic, wood, etc.
➤ Roughing and finishing : By selecting R angles of different sizes, it can meet the needs of roughing and finishing.
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4. Common ball End Mill?

⚫ Solid carbide ball milling cutter :
Features : Made of solid carbide material, with high wear resistance and high hardness.
Application : Suitable for processing high-hardness materials, such as steel, aluminum alloy, cast iron, etc., often used in mold processing and high-precision parts manufacturing.

⚫ High speed steel ball milling cutter :
Features : Made of high-speed steel, with good toughness and chipping resistance.
Application : Suitable for low-speed processing and materials with high toughness requirements, such as ordinary steel and non-ferrous metals.

⚫ Indexable ball milling cutter :
Features : The cutter head is replaceable, and the blades are mostly made of carbide, which has a long service life and is economical.
Application : Suitable for rough machining and semi-finishing in mass production, often used for curved surface processing of large-size parts.

⚫ Obtuse angle ball milling cutter :
Features : The blade angle is blunt and the tip is not sharp, suitable for heavy cutting.
Application : Used for rough machining, especially when machining high-hardness materials, to improve machining efficiency and extend tool life.

⚫ Super hard ball milling cutter :
Features : Made of superhard materials such as diamond, CBN (cubic boron nitride), etc., suitable for processing superhard materials.
Application : Suitable for precision processing of super-hard or brittle materials such as glass, ceramics, and carbon fibers.

⚫ Micro-diameter ball milling cutter :
Features : Micro ball milling cutter is a milling cutter with a very small hemispherical blade, specially used for processing small parts and fine curved surfaces.
Application : Micro ball milling cutters are particularly suitable for high-precision processing of fine curved surfaces in the field of precision manufacturing.
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5. About micro-diameter ball milling cutters :

Micro-diameter ball milling cutter is a ball milling cutter with an extremely small diameter. It is specially designed to process small and fine curved surface features. It is an indispensable tool for precision machining and is suitable for processing curved surfaces with small size and high precision requirements. For processing tasks, the characteristics of micro-diameter ball milling cutters are as follows.

⚫ High precision : Able to accurately process complex three-dimensional surfaces, ensuring high precision and detail.
⚫ Very small diameter : The tool diameter is very small, suitable for processing small curved surfaces and microstructures.
⚫ High-quality materials : Usually made of high-strength materials such as carbide, which can extend tool life.
⚫ Widely used : Commonly used in precision manufacturing fields such as mold manufacturing, microelectronics, and medical equipment.
⚫ Suitable for high-speed machining : Need to operate at high speed to achieve stable and smooth cutting results.

Micro-diameter ball milling cutters can meet various processing needs according to different materials, designs and application levels, from rough machining to finishing, covering a variety of industrial fields, and our 輝儀精密（S&A Tools） also provides several models Micro-diameter ball milling cutter.

MYB-Two-edged high-hardness micro-diameter ball cutter▼ 

MYNB-Two-edged high-hardness micro-diameter long-neck ball knife ▼

UYB-two-edged micro-diameter ball knife▼ 

If there is anything that meets your needs or you have other inquiries, please feel free to contact us!
 

6. How ball End Mill are used in surface milling

Although ball milling cutters are very suitable for processing curved surfaces and are often used for complex workpieces and geometric objects, ball milling cutters can also process flat surfaces, but the current efficiency is not as high as other end mills. If you want to use a ball milling cutter to process flat surfaces, You can try to achieve a flat surface on the workpiece by improving the tool path or designing staged operations.

Due to the characteristics of ball milling cutters, as shown in the figure above, sharp points (sharp concave and convex shapes) will be left first, which will affect the surface roughness of the workpiece. In addition, in order to obtain good surface processing, many overlaps are also required. According to the characteristics and operation mode of the ball milling cutter, it will be a great choice if it is used to process relatively flat parts. It can not only shorten the tool change time but also improve the processing efficiency. In contrast, if the operation For larger parts, the cutting time will become longer, and the efficiency will be difficult to say, and the surface roughness may not be optimal. Therefore, when selecting tool processing, you may use multiple or multiple tool types for processing. When processing, these will all be factors that must be considered to combine the appropriate processing methods for your workpiece.

7. Modern Applications

◼ Mold manufacturing : Ball milling cutters are widely used in injection molds, die-casting molds and other processing operations, and can achieve high-precision mold cavity and core processing.
◼ Aviation field : In aviation field equipment, ball milling cutters can be used to process curved surfaces and complex shapes of aircraft parts to ensure high precision and high reliability of parts.
◼ Automobile industry : used for processing automobile engine parts, body molds, etc. to improve production efficiency and product quality.
◼ Medical devices : Ball milling cutters can provide smooth surfaces and precise dimensions when manufacturing high-precision medical devices and implantable devices, ensuring product safety and reliability.
◼ Other applications : In fields such as electronic product casing processing and art production, ball milling cutters are also widely used.

8. Future Development

With the continuous advancement of technology, ball milling cutters will usher in more innovations and developments in materials, design and applications.
◼ New material application : In the future, ball milling cutters will use more new materials, such as nanomaterials, cemented carbide, etc., which will not only improve the wear resistance and service life of the cutter, but will also be able to be used in more aspects.
◼ Intelligent manufacturing : Combining the Internet of Things and artificial intelligence technology will enable intelligent monitoring and predictive maintenance of ball milling cutters, further improving production efficiency and processing quality, and also promoting the development of new technologies.
◼ Green manufacturing : Develop environmentally friendly ball milling cutters to reduce energy consumption and environmental impact during processing, strike a balance between environmental protection and nature, and promote the sustainable development of the manufacturing industry.
◼ Precision machining technology : With the advancement of precision machining technology, ball milling cutters will be able to achieve higher precision and more complex shape processing requirements, meeting the application needs of more industries.

9. Conclusion

As an important tool in modern mechanical processing, ball milling cutters have a wide range of applications and development potential. With the continuous innovation of technology, ball milling cutters will play an important role in more fields in the future, promoting the manufacturing industry to become more efficient and more efficient. Develop in a smarter and greener direction. The above is the first half of the introduction about ball milling cutters. If you have any requirements or requirements during the reading process, please feel free to contact us at "輝儀精密（S&A Tools）" or inquire about related products. We look forward to you! In the next chapter, we will introduce the common application methods of ball milling cutters, as well as the R angle and usage methods, etc., so stay tuned.
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"How far can this milling cutter go? I really want to know......"
"I don't know which milling cutter is suitable for me, it's really confusing......"
"I have a plan that requires additional precision machining, but I don't know how to execute it......"
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If you have any questions such as the above or want to know more about the article, you can contact us. "S&A Tool" will provide kind replies and consultations to help you solve your current problems !