CNC milling tools, commonly called mills, are indispensable components in CNC machining. These versatile cutting tools shape and transform raw materials into precise and intricate components, meeting the high demands of modern industries. Designing CNC milling tools involves understanding the application’s requirements and translating them into a functional and durable tool. 

Baucor offers an array of shapes, sizes, and configurations, making them adaptable to various machining tasks, from crafting complex geometries to creating slots, pockets, and contours. Mills are effective on materials like metals, plastics, and composites.

2. Defining the mill’s geometry:

Once the requirements for the mill are precise, the tool’s geometry is defined: 

1. Mill type:
   Determine the specific type of tool based on the cutting application, such as end mills for removing material, Back corner rounding end mills for milling a radius on the backside of the workpiece, or dovetail cutters for making dovetail shapes into the workpiece. Baucor offers a wide range of mills; for more details, check the section below, “mill types‎.”
   
   
2. Mill dimensions:
   Define the required dimensions of the mill, including length, diameter, and other critical dimensions, to ensure a precise cut and a proper fit. For example, the width and height of a dovetail cutter must align with the dovetail profile to be cut from the workpiece.
   
   
3. Cutting edge configuration:
   Select the edge type (e.g., square, ball nose, chamfered) based on the required cutting performance. For example, a square edge can produce sharp cuts and precise pockets, while a ball nose is ideal for creating smooth contours or complex 3D surfaces. Chamfered edges are used for beveling or achieving a tapered finish.
4. Mill mounting:
   Define the mill's mounting features, such as clamping, bolting, or a specific mounting mechanism, to guarantee stability, precision, and secure operation during high-speed machining. Consider factors like compatibility with different machine types, quick-change capabilities for efficiency, and robust designs to withstand operational stresses. We offer several mounting geometries. Check the table below (Tool mounting) for more information.
   
   
5. Mill material:
   Select the proper material for the mill based on specific machining requirements. High-speed steel (HSS) offers versatility and cost-effectiveness for general applications, while Carbide provides superior hardness and wear resistance, which is ideal for high-speed operations on rigid materials. Powdered Metal balances toughness and resistance to wear for extreme durability, making it a robust option for demanding environments. These materials ensure the best performance, longevity, and precision in diverse machining tasks.
   
   
6. Coatings and Surface Treatments:
   Enhance tool performance by coating it using Titanium Nitride (TiN), Titanium Aluminum Nitride (TiAlN), or Diamond-Like Carbon (DLC). These coatings reduce friction, improve wear resistance, and significantly extend tool life, particularly in high-speed and high-temperature machining applications.

Mill types: 

Baucor provides various CNC milling tools, each designed for a specific application.

Below are the mills grouped by type:

A. General Purpose Mills

1. End Mills: A standard tool for everyday milling tasks, including cutting, drilling, and shaping.
2. End Mill Neck Relieved: Features a reduced neck diameter for deep cuts or working around obstructions. 

B. Profiling and Contouring Mills

1. Concave Radius Milling Cutter: Shapes concave radii on components for specialized profiles.
2. Back Corner Rounding End Mills: Creates smooth, rounded edges on the reverse side of a part.
3. Corner Rounding End Mill—Double End: This mill rounds edges with cutting tools on both ends, making it efficient in machining. 
4. Corner Rounding End Mill - Single End: Rounds edges with a single cutting end, ideal for specific edge work. 
5. Tapered End Mill: Tapered shape for creating angled surfaces and precise mold features. 
6. Tapered Ball Nose End Mill: This end mill combines a taper and ball nose design, which is excellent for intricate detail work. 
7. Lollipop Cutters: Ideal for machining undercuts and creating complex 3D geometries. 
8. Ball Nose End Mill: Features a rounded tip, ideal for sculpting 3D surfaces and detailed contours. 

C. Slotting and Grooving Mills

1. Dovetail Cutter - with Neck Radius: Designed with a radius at the neck to reduce stress during dovetail creation.
2. Dovetail Cutter: Machines' dovetail slots are commonly used in assembly components. 
3. Dovetail Cutter - with Long Reach: Long-reach version for deeper and harder-to-access dovetail machining.
4. Double Angle Shank Cutters: Creates V-shaped grooves and angular cuts in a single operation. 
5. Keyseat Cutter - Full Radius: Creates rounded keyways for specialized mechanical applications.
6. Keyseat Cutter: Used for cutting keyways in shafts for secure assembly with mechanical keys.
7. Keyseat Cutter - Staggered Tooth: Reduces vibration and chatter with staggered teeth for smoother keyway cutting.

D. Chamfering and Engraving Mills

1. Chamfer Cutters—Pointed: These create beveled edges or chamfers essential for part finishing and assembly preparation.
2. Engraving Cutter Tipped Off: Precision tip for intricate engraving and fine detailing.
3. Engraving Cutters - Pointed: Sharp-pointed tools perfect for detailed engravings and markings.
4. Radius Engraving Cutters: Engraving tools with a radiused tip for smooth, curved markings.
5. Tipped Off Chamfer Cutters: Tailored for beveling with a unique tip shape for precision and consistency.

E. Clearance and Finishing Mills

1. Clearance Cutters - Square End Mill: Flat-ended cutter offering added clearance for finishing operations.
2. Clearance Cutters - Ball End Mill: Provides extra clearance for machining, which is helpful in specific tasks.
3. Chipbreaker End Mill: Efficiently removes material with its serrated cutting edge, reducing chip size during machining.

F. Die Sinking and Specialty Mills

1. Die Sinking Cutters: Precision tools for creating detailed cavities in dies and molds.
2. Porting Tools: Enlarges and refines internal passages, commonly in automotive components.

Before proceeding with production, it's essential to validate the design using numerical analysis methods like finite element analysis (FEA) or prototyping. Rapid prototyping methods, such as 3D printing, allow for a practical assessment of the design’s functionality, ergonomics, and compatibility within the machine. If needed, refine the design based on feedback from the analysis or prototype.

Baucor’s CNC milling tools are crafted with precision and expertise, ensuring high performance, durability, and reliability. Whether you need standard mills or custom-designed solutions, we are committed to delivering tools that empower your machining capabilities.