Posts

Multi-Functional Tools Every Shop Should Have

If there is one thing that all machinists and shop managers can agree on, it’s that time is money. Tool and material costs, employee wages, and keeping the lights on all add up, but most would agree that saving time is one of the best ways to make a shop more efficient.

Tool changes mid-job quickly add up when it comes to cycle times (not to mention tool costs), so using a tool capable of multiple operations whenever possible is an excellent first step. The following multi-functional tools are designed to save time and money at the spindle.

Drill/End Mills

drill mills

One look at Drill/End Mills or “Drill Mills” and it’s obvious that these tools are capable of more than a standard end mill. Two of the intended operations are right in the name (drilling and milling). Besides the obvious, though, drill mills are intended for grooving, spotting, and chamfering, bringing the total to five separate operations.

drill mill operations

Considering the amount of tools normally required to perform all of these common operations, keeping a few drill mills in your tool crib ensures you’re always ready to tackle them, not to mention the potential extra spots in your tool magazine.

Undercutting End Mills

undercutting end mills

Undercutting End Mills, also known as lollipop cutters or spherical ball end mills are surprisingly “well-rounded” tools. Besides milling an undercut feature on a part, which is typically very difficult with a standard end mill, these tools are capable of a few other operations.

undercutting end mill operations

Using an undercutting end mill to deburr in your machine is an excellent way to save time and effort. Some slotting and contouring operations, especially when 5-axis milling, are made far easier with an undercutting end mill, and in some situations, clearance challenges make them necessary.

Double Angle Shank Cutters

double angle shank cutters

Often referred to the “Swiss Army Knife of Machining” due to their versatility, Double Angle Shank Cutters are 6-in1 tools worth keeping on hand in any machine shop. Since these tools cut on all sides of their head, they are useful in a variety of situations.

multi-functional tools

With the ability to thread mill and countersink, Double Angle Shank cutters are perfect for holemaking operations. On top of that, their clearance advantage over standard end mills makes them extremely well suited to a variety of finishing operations in difficult to reach places.

Flat Bottom Tools

flat bottom tools

Flat Bottom Drills and Flat Bottom Counterbores are better suited to holemaking, but they are capable of a large variety of operations. They belong in a category together since their flat bottom geometry is what sets them apart from other tools in the same category. Flat bottom geometry keeps the tool from walking on irregular or angle surfaces and help to correct, straighten, or flatten features created by non-flat bottom tools.

Flat bottom drills are designed for the following operations:

multi-functional tools

While similar in some aspects, flat bottom counterbores are particularly well-suited for these uses:

flat bottom tools

Adjustable Chamfer Cutters

adjustable chamfer cutters

As discussed in a previous post, chamfer mills are capable of more than just chamfering – they are also well-suited for beveling, deburring, spotting, and countersinking. However, these adjustable chamfer cutters aren’t limited to a single angle per side – with a quick adjustment to the carbide insert you can mill any angle from 10° to 80°.

chamfer cutter inserts

When you account for the replaceable insert and the range of angles, this tool has a very high potential for time and tool cost savings.

Tools that are capable of a variety of operations are useful to just about any machine shop. Keeping your tool crib stocked with some or all of these multi-functional tools greatly increases your shop’s flexibility and decreases the chances of being unprepared for a job.

The Multiple Uses of a Chamfer Mill

A chamfer mill, or a chamfer cutter, is one of the most common tools used by machinists daily. When creating a part, machining operations can oftentimes leave a sharp edge on a workpiece. A chamfer mill eliminates sharp edges, leaving a sloped surface, or a chamfer, instead. In doing so, the part will be stronger and more aesthetically appealing to its eventual user.

This singular tool can provide many cost-saving benefits to machinists. Aside from the namesake operation it performs on a part, a chamfer mill can be used for several machining operations including beveling, deburring, countersinking, and spotting.

Chamfer Mill for Beveling

The terms “chamfer” and “bevel” are often used interchangeably. These two features, while similar, actually have two different definitions. While a chamfer impacts a portion of the side of a workpiece – specifically the edge of a part, a bevel angles the entire side of what was a squared-off part feature. Thus, the side of a part can feature two chamfers, or only one bevel (Figure 1).

A chamfer mill, however, can perform both operations. The two features are equivalent in both geometry, and how they are machined.  A chamfer mill will create both part features in the exact same fashion; a bevel just may use a larger portion of the cutting surface, or may require multiple passes to create a large part feature.

Chamfer Mill for Deburring

Like many other versatile tools, a chamfer mill can be used to easily and swiftly deburr a part during the CNC machining process. In doing so, efficiency is maintained as manual deburring – a time exhaustive process – isn’t necessary.

A chamfer mill’s angled cutting surface makes it a great tool for deburring workpiece edges.  Because a very small amount of the chamfer cutter’s cutting face will be used, a simple adjustment to running parameters will allow for simple deburring operations using a very light cut depth.

Chamfer Mill for Spotting & Countersinking

Drilling precise, clean, and aesthetically appealing holes into a part is not a one-step process. In fact, some use up to four different tools to machine a perfect hole: spotting drill, drill, flat bottom counterbore, and countersink. However, a chamfer cutter is often used to perform two of these operations simultaneously.

By using a pointed chamfer cutter with a diameter larger than that of the hole being drilled, a machinist can spot and countersink the hole in one operation prior to its creation. Tipped-off Chamfer  Cutters are unable to perform a spotting operation because they are non-center cutting. By spotting a hole, the drill has a clear starting point. This works to alleviate walking during the drilling process, which in turn drastically reduces the chance of misaligned holes. By countersinking a hole, the screw sits flush with the part, which is often a requirement for many parts in the aerospace industry.

One consideration to keep in mind is that a carbide spot drill should always have an angle larger than that of the drill following it. However, many countersinks have angles that are smaller than most drill points.  This creates a dilemma in choosing a chamfer tool for both spotting and countersinking, as they can reduce the number of tools needed, but do not see the full benefit of a spot drill with a proper angle.

Key Takeaways

A chamfer mill, also known as a chamfer cutter, is a tool that can perform several machining operations including chamfering, beveling, deburring, spotting, and countersinking. Due to this versatility, chamfer mills are an essential part of every machinist’s arsenal.  All that’s needed to run them is these various operations is a slight change to running parameters and depth of cut.

6 Uses of Double Angle Shank Cutters

A Double Angle Shank Cutter is often referred to as the “Swiss Army Knife of Machining” due to its extreme versatility. This singular tool can be used for chamfering, back chamfering, V-groove milling, deburring, and countersinking. Below, we’ll learn the nuances of each operation, and why a Double Angle Shank Cutter might is an excellent tool to have on hand in any machine shop.


1. Thread Milling

Both in purpose and look, a Double Angle Shank Cutter is very similar to that of a single-form thread mill. Single-form thread mills are more versatile than multi-form thread mills, as they are not locked into a fixed pitch. Double Angle Shank Cutters that have a 60° angle can create internal and external 60° Unified National (UN) and metric threads. Double Angle Shank Cutters with a 55° angle can be used to thread 55° British Standard Pipe Threads (BSPT). To determine the thread sizes that various Double Angle Shank Cutters can produce, it’s helpful to consult thread fit charts, which pair appropriate cutter diameters to the thread size needed.


2. Chamfering

Depending on the requirements of your chamfering operation, and the angle of the chamfer you’re creating on your part, a Double Angle Shank Cutter might be appropriate. The angle of the top or bottom of the cutting face of the tool (called out below in as a B1 dimension), will determine the angle of your part’s chamfer. The area marked in red in Figures 2 and 3 below indicate the cutting portion for your chamfering and back chamfering (leaving a chamfer on the bottom of a part) operation.

For more information on the angles of Double Angle Shank Cutters, view Harvey Tool’s helpful guide: “Angles Untangled.”


3. Back Chamfering

Consider a through-hole that has a burr or tear-out caused from drilling the back of a workpiece. Reorienting the workpiece and relocating the hole is time-consuming, and it may be difficult to accurately finish the hole. In a case like this, back chamfering the burred hole without changing the setup is a preferred method. Put simply, the ability to accurately chamfer not only the top – but also the bottom of a part without needing to refasten the workpiece in your machine will save valuable time and money.

For best results when chamfering with Double Angle Shank Cutters, use a stepping over technique with diminishing passes as the radial engagement increases. This strategy helps to manage the amount of contact along the angle and can significantly avoid tool deflection.


4. Machining V-Grooves

A Double Angle Shank Cutter is commonly applied for machining V-groove profiles because of its cutting head, which is perpendicular to the tool centerline. This provides effective cutting action, even at a low spindle speed. A low tip speed can lead to issues with other tools, such as Chamfer Cutters, where the pointed profile is on-center of the tool.


5. Deburring

The task of hand-deburring parts can be tiresome for you, and cost inefficient for your shop. It can also lead to inaccuracies in parts that require precise dimensions. Double Angle Shank Cutters can be used to debur a part right in your CNC machine. By doing so, the process of finishing a part is made simple, fast, and accurate. Of course, ensuring proper clearance prior to machining the bottom of a machined hole is pivotal.

Other useful and versatile tools to have on-hand for quick CNC deburring include deburring end mills, back deburring mills, undercutting end mills, and chamfer cutters.


6. Countersinking

Countersinking a part  is done so a screw, nail, or bolt is able to sit flush with the part surface. Using specialty profile tooling can help enlarge the rim of a drilled hole and bevel the sides for a screw to sit accurately. A Double Angle Shank Cutter can also perform this operation by using the bottom portion of its cutting face.


Because of its ability to perform six different operations, Double Angle Shank Cutters are an ideal tool to keep in your tool carousel. In a bind, these tool forms can mill threads, chamfer, back chamfer, machine v-grooves, deburr in your CNC machine, and countersink. This versatility makes it a machining favorite and can offer shops boosted productivity by eliminating the need to flip parts, deburr by hand, or carry multiple tool forms.

For more on Harvey Tool Double Angle Shank Cutters, Click Here.