Considering the machining world, milling is known as a basic process, which deals with the use of rotary cutters to get rid of material from a specific workpiece. There are two well-known milling techniques, which are end milling and face milling. Primarily, these two techniques have differences in tooling, face mill vs end mill.
Both methods are unique and different from each other. This article aims to discuss the differences, applications, benefits, and pitfalls of face milling vs end milling. This will guide you about their features and determine if they suit your machining projects.
Face Milling vs End Milling: What are the Differences?
To understand the difference between face milling and end milling, it’s important to know what both milling techniques are all about.
What’s Face Milling?
With face milling, you can create top-notch flat surfaces making use of a shell mill, end mill, or fly cutter. Using these face milling tools means that you can easily swap them out because they have several head inserts. Place the material you plan to cut face up and form an angle of 90 degrees to the axis of the cutter. After modifying the necessary settings such as the feed rate and spindle speed, hold the material to stay in place to help you start cutting.
You may be lucky to get the cuts in just one pass, however, if you fail to, don’t be too hard on yourself, because even the experts may need more than one pass. With face milling, you are sure to remove much of the material faster, however, it only delivers a medium quality surface finish.
Furthermore, face milling is possible with different metals including titanium, brass, aluminum, and steel and the use the method to level raised edges and surfaces, and also making pockets, and parallel surfaces, too. Large diameter tools are usually used for the face-milling process, these include ball nose, chamfer tipped, and radius tipped.
Read More: What’s Face Milling?
What’s End Milling?
End milling offers a bit more versatility and is useful in making cavities, shoulders, slots, pockets, and profiles. Meanwhile, the workpiece stays in a parallel form to the tool spindles. Also, it gets rid of material using a tool having cutting edges on the peripheral area (sides) and the end face (flat part).
Furthermore, it comes with a unique design that ensures additional tasks, including the cutting of different shapes, making of die cavities, engraving, contours, etc. As regards preparation, end milling and face milling are similar; however, for the end milling jobs, you must set up the machine properly and set the material in the best position possible that allows for proper cutting.
Using this procedure means that you require both perpendicular and axial cutting capacities for things relating to contouring, slotting, making keyways, counterboring, profiles, etc. In contrast to face milling, end milling doesn’t come with the best quality finish, which usually falls between 0.29 µm and 0.95 µm. However, it still has a good look.
This process requires some set of machine tools, these include:
- Ball nose end mill: Used in cutting the contoured surfaces in molds and dies
- Square or flat end mills: They perform the usual end milling tasks.
- Corner rounding end mill: This is used to cut round edges
- Tapered end mill: Specially for cutting materials utilizing a mold or a die
- Corner radius end mill: Help to cut corner radii
- Keyway end mill: used to cut keyway slots
- Drill mill: Made for chamfering, spotting, drilling, and countersinking
- Roughing end mill: Helps in removing large amounts of materials; however a rough surface usually results
4 Key Differences Between Face Milling and End Milling
In this section, we’ll be considering the main differences between face milling vs end milling considering factors such as cutting orientation and tool usage, quality of surface finish, applications for various materials, cutting depth, and cutter types and geometry. Let’s get started.
Cutting Orientation and Tool Usage
For face milling, the cutting orientation requires that there is a perpendicular distance between the cutting edges and the surface of the workpiece. On the other hand, for end milling, its cutting edges are usually situated on its sides and face.
Regarding tool usage, face mills have many cutting edges and a larger diameter that allows them to work with a larger material. End mills, on the other hand, have a smaller diameter, thereby dealing with less material.
Surface Finish Quality
Face milling is more appropriate and faster for huge projects. Its surface finish is usually smoother since the design allows for frequent contact with the surface of the workpiece. Furthermore, to get aesthetic designs for the surface finish, you may use a wiper insert along with the standard insert.
Furthermore, end milling can create comprehensive finishes on contours and complex shapes. Their versatility ensures that they create exceptional surface finishes even in complex areas.
Applications and Suitability for Various Materials
Face milling is suitable for the machining of flat and large surfaces efficiently, attaining perpendicular features, and ensuring the workpiece meets the milling requirements. Furthermore, it is suitable for different metals, which include titanium, steel, brass, and aluminum. A face milling project also helps in creating recesses and pockets, creating parallel surfaces and leveling surfaces.
For end milling, it is useful in creating precise holes, profiles, slots, and contours. It is applicable in operations related to roughing and finishing operations. Also, it works well for delicate machining tasks, which require detailed features. Even more, it is useful in the milling of different materials, which include composites, metals, and non-metals.
Cutter Types and Geometry
Face mill cutters are used for face milling, which are designed to make the workpiece’s surface flat. On the contrary end milling mainly uses end mills that are available in different types like corner radius, ball nose, and square end mill.
Furthermore, face mills have many cutting edges and larger diameters that allow them to cover large surface areas in one pass. For end mills, they feature smaller diameters as well as cutting edges that suit pocketing, slotting, and accurate profiling.
Cutting Depth
Both end milling and face milling tasks ensure different cutting depths, which are dependent on some requirements for the machining processes. Adjusting the cutting depth is possible, depending on some factors including preferred surface finish, machine capabilities, and types of material.
How Face Milling and End Milling Work Together
Face and end milling are well-known milling operations, which accomplish different tasks. They can however work together in CNC machining as well as for prototyping and custom part manufacturing
Combining Face Milling and End Milling in Machining
Although face milling vs end milling has many differences, it is possible to combine them in a single machining setup. Below are some ways:
Face milling helps to get rid of huge quantities of materials from flat work surfaces. The axis of rotation of the cutting tool forms a perpendicular distance from the surface of the workpiece. Using face milling is great for creating recesses and pockets, parallel surfaces, and leveling surfaces.
End milling plays a role in versatility and precision. This makes it useful for small components and very complex shapes. They also work with less material compared to face milling, thereby ensuring beer precision and control.
Using Face and End Mills for Prototyping and Custom Part Manufacturing
During prototyping and custom part manufacturing, face milling is great for producing high-quality flat surfaces. To make this happen, ensure you attach the workpiece firmly to your machine table, placing it perpendicularly to the axis of the cutter. This ensures that it doesn’t slip.
Also, make sure that you set the feed rate and spindle speed to promote cutting in the appropriate position. You should also make the cutting automated using computer numerical control and before you remove the chips, ensure that you cool the surface and tool.
For end milling, it is great for profiling, pocketing, and complex shapes. During prototyping, consider the type of end mill, which includes square-end, V-bits, ball end mills, etc., because each type serves different applications.
Also, consider the number of flutes. There are 2 to 4 flutes in end mills. With more flutes, you can increase the feed rates and then deliver a high-quality surface finish. Fewer flutes cause less accumulation of heat. Furthermore, end milling can be used for creating slots.
Applications of Face Milling and End Milling
Face Milling Applications in Different Industries
| Industries | Applications | Why Face Milling |
| Aerospace Industry | Wing sections of airplanes | It creates precise and smooth surfaces, which are important for parts utilized in the aerospace industry |
| Automotive Industry | Machining engine parts and Cylinder heads | It is an efficient and versatile technique that produces high-quality and smooth surfaces, even on large components |
| Heavy Equipment and Machinery | Making uneven surfaces flat, like machine bases and structural items. | It prepares the surface for more work and ensures that the parts feature smooth finishes and precise dimensions |
| Tool and Die Making | Mold Making Die prototyping and manufacturing | It can create intricate shapes, create smooth surfaces by removing materials evenly, and work on different surfaces and materials. |
| Energy and Power Generation | Designing tools Cutting energy Modeling | It is energy efficient and can utilize different cutting tools including end mill, shell mill, or fly cutter. |
End Milling Applications in Different Industries
| Applications | Why End Milling | |
| Aerospace Industry | Components of aircraft like structural parts, turbine blades, and engines | End milling is important here due to its reliability, efficiency, and precision in creating complex components |
| Automotive Industry | For cutting external and internal shapes of cars Engraving texts in car parts Creating complex parts in automotive like frameworks and gears | It is a machining process that creates holes and shapes in Workpieces. This makes them useful in profile milling, and creating molds and prototypes |
| Mold and Die Making | Creating molds and dies as well as other tooling | The use of end milling in mold and die making helps in creating contours and complex shapes with accuracy. It is also versatile and creates high-quality finishes |
| Electronics Industry | Engraving, slotting, profiling, and plunging | For shaping the eventual form of different components. It is also useful in creating complex designs on electronic enclosures, PCBs, etc. |
| Medical Device Manufacturing | Creating detailed and precise components for medical devices like implants, prosthetics, and surgical instruments | Useful here due to its importance in creating intricate designs as well as its efficiency in producing complex parts. It is also versatile and can work with different materials including composites, plastics, and metals. |
| Consumer Electronics | Profile milling, engraving, detailing, plunging, and drilling | End milling is useful here because it helps in creating a part’s external shape. It adds details to parts and creates flat and smooth surfaces on a workpiece. |
Benefits and Drawbacks of Face Milling
Benefits of Face Milling
High Material Removal Rates
Face milling can remove large material from a workpiece’s surface. Due to its high removal rate, it reduces machining time and cost of production. Also, it is an ideal machining process in large-scale production.
Superior Flatness and Surface Finish
If you compare the finishing of face milling vs end milling parts, Face milling can help you achieve a flat and even surface. This machining method uses a cutter that can cover a large surface area in a pass. However, choosing the right cutter can help you achieve the desired smoothness of the surface. Since face milling creates a fine even surface, it is ideal for applications where appearance is a major concern.
Ability to Handle Large Workpieces
When handling large workpieces, face milling is a suitable choice. Since it has multiple cutting edges, this machining method is capable of cutting through a large workpiece while achieving consistency across the surfaces.
Multiple Cutting Edges
Face mills have multiple cutting edges which makes it easier for them to quickly cut large quantities of material.
Flexibility in Cutting Depth
Face milling is compatible with many types of materials ranging from plastics to metal to wood and even composites. Also, it is suitable for use in many applications due to its versatility. From achieving even surfaces to cutting through large surfaces, face milling has become a popular choice amongst manufacturers.
Drawbacks of Face Milling
High cost of tooling
Face mills designed to carry out high-speed machining operations are usually very expensive. Due to the high cost of tooling, face milling isn’t suitable for small scale production. You can reduce costs by employing face mills with replaceable inserts; however, the initial cost can be high, particularly for complex operations.
Perfect for only Flat WorkPieces
Face milling is perfect for creating a smooth surface with a high degree of flatness. This machining process isn’t an ideal choice for complex geometries. You can’t integrate face milling in applications that require intricate cuts or machining non-flat surfaces. The best machining method for such procedures is end milling.
Not Suitable for Complex Geometries
Face mills aren’t designed to create complex shapes, intricate cuts, and contours. Therefore, its application is limited.
Benefits and Drawbacks of End Milling
Benefits of End Milling
Precision and Accuracy
End milling delivers precise and accurate cuts. This machining process removes material from the workpiece while ensuring the shape of the item meets the desired dimensions. End milling focuses on creating certain profiles, features, and surfaces with accuracy. Therefore, it is mostly suitable for applications that require high tolerances.
Ability to Machine Complex Geometries
End milling is best employed for creating complex geometries since it can cut in multiple directions at the same time. Also, it can create complex shapes, pockets, slots, and many holes of different sizes. Common use cases of this process include profile cutting, complex 3D machining tasks, and contouring.
Machining of Internal Features
This is another important benefit that distinguishes end milling from other machining operations. It can generate internal features, which can be complex for other machining processes to achieve.
Versatility in Operations
Since end milling can perform different machining operations a wide range of industries rely heavily on it. For instance, end milling is used in the production of surgical equipment, dental prosthetics, and other medical devices. This machining method can create dies, molds, different types of tooling, and intricate designs in furniture. Also, it can cut plastic, aluminum, wood, and even composite materials.
Cost-Effective for Small Batch Production
It is a cost-effective solution for small production runs. The end milling process is automated and as such, hastens production. With end millers, manufacturers can create parts within hours. Also, end milling is ideal in prototyping and production as it enables manufacturers to scale through the trial process to moderate production.
Drawbacks of End Milling
Tool Deflection
Tool deflection is a major drawback because end mills wear out easily, especially when used on hard materials. This can result in a quick end in tool life and high production costs.
Higher wear on cutting edges
The cutting edges of end mills are more prone to wear and tear.
Less effective for large surfaces
End milling doesn’t work well on flat and large surfaces due to the orientation of their cutting edges. Face cutters are the preferred choice for this scenario.
Difficulty with Long Thin features
Due to its fewer cutting edges and smaller diameter, end milling can’t machine a workpiece with long thin features.
When to Use Face Milling vs End Milling
The difference between face milling and end milling also makes them favorable for distinct machining scenarios. Face milling is a perfect option when you need it to make a surface flat and create different features on that surface. This machining process is often integrated in industries where large components need to be machined with precision and fine surface finish in mind.
Besides, face milling is suitable for machining aluminum, steel, and other metals that need a smooth surface finish. You can also use face milling when you need to prepare parts for assembly. This milling method achieves excellent flatness in large components like engine blocks and machine frames before fitting them with other parts.
Furthermore, face milling is best adopted when time is of the essence as it can quickly remove large materials within a short time. It is a better option for large-scale projects since it is faster and more efficient.
End mills feature a smaller diameter which helps them achieve more precise cuts. Due to their smaller diameter, they can get into tighter spaces. This makes them the most suitable option in applications where precision is a major concern. You can use end milling for the production of complex parts, mold, and dies. It is widely integrated in applications that need intricate designs like aerospace and medical devices.
Another common application where end milling has proved its efficiency is in the creation of slots and pockets. End mills can remove material in a more controlled manner to create features like cavities and keyways in a workpiece.
In addition, you can use end milling for materials like plastics, metals, and composites. This machining method can create intricate cuts, making it ideal for complex features and shapes.
Choosing the Right Process for Your Project
Some factors determine the most suitable machining process for your project. These factors include the specific requirements of the desired project, the type of material being machines, the complexity of the design, and the desired finish. While each machining method has its strengths, it is crucial you understand the differences in their end results.
In general, face milling is a popular choice if you need to remove large quantities of materials from a flat surface quickly. Also, this machining process is great for large-scale production, especially horizontal surfaces.
However, if creating complex designs with precision is of great concern, then end milling is the go-to technique. End milling offers versatility and flexibility and is compatible with vertical mills . Therefore, the type of machine you will be using determines the process to choose.
Cost and Efficiency Considerations
Cost and efficiency are major factors to consider when choosing between face milling and end milling. End milling is a cost effective option as it is suitable for making intricate cuts and complex shapes. Also, it is very efficient as it serves other functions like slotting, pocketing, and contouring.
On the other hand, face milling can be quite expensive due to the cost of tooling. Therefore, it isn’t an ideal choice for small scale production. The bulkiness and desired outcome of your project will determine the best machining operation to choose.
Conclusion
We hope we’ve been able to clarify the differences between the face mill vs end mill. RapidDirect offers a wide variety of manufacturing capabilities, providing customers with machining and milling services for production and prototyping parts. Wish to widen your knowledge regarding end milling and face million, contact our representatives today and get a free quote.
Frequently Asked Questions
Face mill vs end mill work differently in terms of the number of cutting edges, the orientation of their cutting edges, diameters, and applications.
While face mills have multiple cutting edges and large diameters, end mills have fewer cutting edges and small diameters. As a result of this, the face mill is capable of covering a large surface in just one pass.
Furthermore, the cutting edges of a face mill are placed in a perpendicular manner to the workpiece surface. On the hand, the cutting edges of the end mill are positioned on its periphery and face. Face mill is suitable for large flat surfaces while end mill is ideal for creating slots and drilling accurate holes.
Face milling and side milling are two types of milling processes that differ in terms of their operation and the positioning of their milling cutter.
Face milling is a more straightforward process that involves placing your type of milling cutter perpendicular to the workpiece. In this process, only the top of the face milling cutter performs the milling task. This makes them a suitable choice in applications where fine surface finishes are required.
On the other hand, side milling uses peripheral edges to machine surfaces that are angular or parallel to the machining table. This process offers precise orientation by ensuring the rotational axis of the cutter is perpendicular to the surface. Side milling is the best machining method for creating flat surfaces on work pieces.
Both end milling and slab milling are two types of machining operations, with each having different operation modes, different cutting edges, and applications.
Slab milling is commonly used in removing large quantities of material. It involves placing the machined surface parallel to the cutting edge in the periphery of the tool. This machining method is ideal in applications that require high precision finishing.
End milling is more versatile than slab milling as it can be used in creating pockets, cavities, slots, and profiles. This machining method uses a cutting tool to create axial cuts into a workpiece. End mills have cutting teeth on each peripheral side and more cutting teeth on the tips.
Yes, you can face a mill with an end mill. This is because end mills can serve the function of face mills. However, face mills can’t carry out end milling tasks. While end mills can create pockets and slots, face mills are only capable of machining a surface.
Also, end mills are more versatile as they can perform other tasks like engraving, making die cavities, and contouring. Although face mills and end mills remove material from a workpiece, face mills are perfect for flat surfaces while end mills are great for many things. Face mills offer finer surface finishing compared to end mills.
