Tag Archive for: Machining

ITL TV: Stop the Chatter: How End Mill Geometry Reduces Vibration

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Chatter at the machine is one of the most frustrating problems a machinist can face. In this episode of In The Loupe TV, Cutting Tool Counselor Don Grandt explains how modern end mill geometry tackles the problem at its source by breaking up impact frequency.

Don walks through three key design features found on high-performance end mills: variable pitch, variable helix, and progressive helix. Each one works to disrupt the harmonic patterns that cause vibration, giving you a cleaner finish, longer tool life, and more consistent cutting action.

If you’re still running symmetrical end mills for finish work, this is the episode that will change how you spec your tools.

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ITL TV: Where the Metal Meets the Mill

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In this episode of In The Loupe TV, the “Cutting Tool Counselor,” Don Grandt, breaks down points of contact and why they matter in machining applications. Learn how to identify where your tool is engaging the material, how many points of contact are in the cut, and how optimizing that engagement can improve performance.

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ITL TV: How HEM Toolpaths Tackle Heat and Vibration

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Have you ever wondered what really causes premature tool failure? The “Cutting Tool Counselor,” Don Grandt, is here to uncover the two biggest culprits: heat and vibration. In this episode of In The Loupe TV, Don explains how High Efficiency Machining (HEM) toolpaths are designed to combat both, helping you achieve smoother cuts, longer tool life, and maximum efficiency at the spindle. Learn how HEM toolpaths like dynamic, adaptive, and prophet milling strategies manage heat buildup, reduce chatter, and keep you from killing your end mill.

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In the Loupe TV: Understanding Tool Engagement Angle

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Have you ever wondered what really drives the success of High Efficiency Machining (HEM) toolpaths like Dynamic Milling, Adaptive Clearing, and Trochoidal Milling? The “Cutting Tool Counselor,” Don Grandt, is back to reveal the hidden key: Tool Engagement Angle (TEA). In this episode of In The Loupe TV, Don explains how optimizing TEA can help you make the most of your HEM toolpaths, boost productivity at the spindle, and get the best results from your cutting tools. 

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Supporting Precision in Mold, Tool & Die Applications

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Mold, Tool, and Die manufacturing demands a high level of precision. Whether you’re machining hardened tool steels, creating detailed mold cavities, or producing dies with complex geometries, the tooling used plays a critical role in ensuring consistent, repeatable results. To explore the full selection of tools relevant to this industry, including application-specific geometries and coatings, visit Harvey Tool’s Mold, Tool & Die Featured Solutions page.

Harvey Tool offers a comprehensive range of tools specifically engineered to meet the unique challenges of the Mold, Tool & Die industry. From tools designed to reach deep cavities to those that maintain surface finish in demanding materials, this offering is built to support precision and reliability throughout the machining process.

Tools included in this lineup are:

  • CVD Diamond End Mills– This Harvey Tool lineup of Diamond Tooling for Non-Ferrous Materials features true crystalline CVD diamond on a solid carbide substrate, making it ideal for machining graphite, composites, green carbide, and green ceramics.
  • End Mills for Hardened Steels– Engineered for hardened steels from 46Rc to 68Rc, this tool includes the latest generation AlTiN Nano coating for enhanced hardness and thermal resistance.

  • End Mills for Aluminum Alloys– We know a part is only as successful as its finish. That’s why our aluminum finishing solutions are crafted for mirror-like surface quality.   

  • End Mills for Medium Alloy Steels– Engineered for versatility, these CNC-ground, AlTiN-coated tools excel in machining stainless, tool, and medium alloy steels.
  • Miniature Tapered End Mills– Tackling deep part features? Harvey Tool’s tapered Miniature End Mills offer unique geometries that take the challenge out of tough-to-reach cuts.

Diamond End Mills for Abrasive and Non-Ferrous Materials

Diamond tooling is essential to many moldmaking processes, particularly during electrode production and when machining non-metallic materials. Harvey Tool’s offering includes a wide selection of Diamond End Mills designed for use in abrasive and non-ferrous materials such as graphite, green carbide, green ceramics, and composites—materials commonly encountered in mold and die work.

These tools feature a CVD (Chemical Vapor Deposition) coating to promote longer tool life and uphold tight tolerances over extended machining cycles.

Highlighted tooling includes:

Diamond End Mills are frequently used in electrode machining for EDM (Electrical Discharge Machining), where precision in non-metallic workpieces directly influences final mold quality.

All tools in the Mold, Tool & Die offering are fully stocked and available to ship same day, helping to reduce lead times and keep your production on schedule.

To view the full offering, including tools with specialized geometries and coatings, visit the Mold, Tool & Die Solutions page.

A Closer Look at Helical Solutions’ Tapered End Mills

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Helical Solutions offers a variety of Tapered End Mills designed to enhance performance and efficiency in tapered wall applications. In this blog post, we’ll dive into the geometry of tapered end mills and explore their common applications to understand when they could be utilized to optimize your CNC machining application.

Tapered End Mill Geometry

Tapered End Mills bring many advantages to machining compared to standard end mills, but what is a Tapered End Mill? A standard end mill will have the same cutting diameter throughout the whole length of cut, whereas a taper mills starts at the shank or neck at a larger diameter and tapers down at a specific angle.

The angle of the taper can vary, but Helical Solutions’ tools feature angles ranging from .05° to 5°, which allows for a broad spectrum of cutting operations. A tapered length of cut or tapered neck can also provide increased strength and rigidity, compared to that of a standard end mill. Having a tapered length of cut makes it easier to create flat tapered walls on 3-axis machines and leads to a better finish.

Tapered End Mill

Standard End Mill

Common Taper Mill Applications

Tapered End Mills are used in any machining process that requires an angled surface. These tools are engineered for light profiling and finishing applications in mold and die pockets and other tapered wall applications.

Mold & Die Applications

Mold and die applications are a mass production manufacturing method that consists of shaping different types of metals and other materials. Molds are used to shape metals, allowing them to become solid in the mold, while dies use a mechanical force to cut the material into the desired shape.

A couple examples of mold and die applications are plastic bottles, car body parts, electronic components, cutlery, coins, and metal stamping parts.

Mold Tool & Die Example

Tapered End Mills Profiles

Taper mills are great for profiling with the ball nose version, and for light finishing and creating required draft angles with the square version. Which style is right for you?

Ball Nose Taper Mills

Ball Nose Tapered End Mills are great for profiling because the full radius at the bottom eliminates sharp edges, which leads to a smoother process.

Square Profile Tooling

The square version of the tapered end mill has a higher flute count and helix angle with a sharp cutting edge. This is better for light finishes on the walls of tools.

The draft angle determined in the design process is the amount of mold design can be tapered. A draft angle is a strategic angle or slope designed in the mold. The tapered angle in the tool allows for the draft angle to be formed easier compared to a straight shanked end mill. Having a draft angle in the mold allows for easier removal of the part so it does not get stuck to the mold.

Helical Solutions’ Tapered End Mills

Helical Solutions’ offering of Tapered End Mills feature a tapered profile design, variable pitch geometry for reduced harmonics and increased feed rates, and Aplus coating for increased performance in Cast Iron, Steel, and even Stainless Steel. These tools are offered in a 4 Flute Ball style, and a 5 Flute Square style, so you can select the end profile that best suits your specific toolpath.

Helical’s Tapered End Mills

4 Flute Ball (HTPR-4)

Helical’s 4 Flute Ball Tapered End Mills (HTPR-4) are fully stocked in 6 different angles per side (0.5°, 1°, 1.5°, 2°, 3°, 5°), and in 3 different cutter diameters (1/8”, 3/16”, ¼”). These tools feature a ball nose profile, allowing them to excel in a variety of different applications from 3D contouring and profiling to slotting. A Ball Nose End Mill has a full form radius, allowing machinists to utilize the entire radius when contouring and finishing a 3D surface.

5 Flute Square (HPTR-5)

Helical’s 5 Flute Square Tapered End Mills (HTPR-5) is also is also fully stocked 6 different angles per side (0.5°, 1°, 1.5°, 2°, 3°, 5°), and in 3 different cutter diameters (1/8”, 3/16”, ¼”). These tools feature a square profile for more precise finishing and the 5 flute design creates a larger core, allowing for better tool strength in roughing applications.

Taper Mill Tooling Wrapped-up

By understanding the unique features and advantages of this tooling, machinists can make informed decisions and achieve superior results in their projects. These feature unique geometry that enhances machining capabilities and ensures reliability and accuracy across a range of tapered wall applications.

Harvey Performance Company – CNC Cutting Tool Survey 

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To thank survey respondents for completing this survey, we will randomly select 1 winner each day on the following days: 

Week 1: Monday, January 5th through Friday January 9th 2026 (5 winners).

All survey submissions will be entered for a chance to win one of five $250 Digital Visa Gift Cards. Winners will be selected at random at approximately 4:45 PM EST on the dates specified above and will be announced on the official Harvey Performance Company social media channels, including LinkedIn, Instagram, and Facebook. Winners will also be notified via email or phone. Please note that an email address is required to facilitate the delivery of the digital gift card. 

At Harvey Performance Company, we are committed to delivering exceptional products and services, and your perspectives play a pivotal role in shaping our future endeavors. This survey has been crafted with the intention of understanding how our brands are currently serving you, our valued customers. 

How to Participate 

To enter the giveaway, simply complete the survey. Please note that providing your email address is required to facilitate prize delivery should you be selected as a winner. 

Official Contest Rules 

Contest Dates: 

The contest will run from Monday, January 5th, 2026, to Friday, January 9th, 2026. Entries that are submitted before or after the contest period will not be considered for the giveaway. 

Prizes: 
All completed submissions will be considered for one of the five $250 Digital Visa Gift Card prizes.
Winners will be selected at random at approximately 4:45 PM EST on the dates specified above and will be announced on the official Harvey Performance Company social media channels, including LinkedIn, Instagram, and Facebook. Winners will also be notified via email or phone. Please note that an email address is required to facilitate the delivery of the digital gift card. 

Full Details: 
NO PURCHASE IS NECESSARY TO ENTER OR WIN. MAKING A PURCHASE WILL NOT INCREASE YOUR CHANCES OF WINNING. ENTRY INTO THIS GIVEWAY CONSTITUTES THE ACCEPTANCE OF THESE OFFICIAL RULES. VOID WHERE PROHIBITED BY LAW. 

By participating in the Harvey Performance CNC Cutting Tooling Survey, you agree to these official rules (the “Rules”), which are a contract, so read them carefully before participating. Without limitation, this contract includes indemnities to the Released Parties (defined below) from you and a limitation of your rights and remedies. You must follow these Rules to enter and be eligible to receive a prize in connection with the survey giveaway. 

DURATION:  Begins on Monday January 5th, 2026, at 8:00 AM EST and ends January 9th, 2026, at 5:15 PM EST (“Survey Period”).  The computer clock of Harvey Performance Company, LLC (“Sponsor”) is the official time-keeping device for the survey giveaway. 

ELIGIBILITY: The survey giveaway is open only to legal permanent residents of the United States (excluding Puerto Rico, and the U.S. Territories and Possessions) who are 21 years of age or older as of the date of entry. Employees, officers, and directors of Sponsor along with its affiliates, subsidiaries, advertising, contest, fulfillment, and marketing agencies, (collectively, “Promotion Parties”) their immediate families (parent, child, sibling & spouse, and their respective spouses, regardless of where they reside) and persons living in the same households as such individuals (whether related or not) are not eligible to participate in survey giveaway. By participating, you agree to these Rules and to the decisions of the Sponsor, which are final and binding in all respects.  In addition, to be eligible to win: (i) consent to the use of your rights of publicity, (ii) assume all tax liabilities, (iii) waive all claims against Sponsor and Promotion Parties, and (iv) consent to the publication of your full first name, last name initial, and/or the city and state in which you work or live (v) confirm your eligibility (collectively “Affidavits and Waivers”). This survey giveaway is void in any jurisdiction not listed above and where prohibited by law, rule, or regulation. 

HOW TO ENTER: Follow the directions and complete the survey and submission form at the end of the survey.  

An email address is required to be entered to win, however we may call you if your name is selected. Otherwise, you will not be contacted regarding the outcome. 

PRIVACY POLICY:  Information collected in connection with this Sweepstakes will be used in accordance with Sponsor’s Official Privacy Policy (available at https://www.harveyperformance.com/privacy-policy/ and these Rules. In the event of any discrepancy between Sponsor’s Privacy Policy and these Rules, Sponsor’s Privacy Policy shall control and govern. 

LIMITATIONS: The maximum number of entries allowed during the Sweepstakes is 1 per person. 

Sponsor is not responsible for any entry that is lost, late, misdirected or undeliverable, whether due to system errors, omissions, interruption, deletions, defects, delay in operations or transmissions, theft or destruction or failures, faulty transmissions or other telecommunications malfunctions, entries not received resulting from any hardware or software failures of any kind, lost or unavailable network connections, failed, incomplete or garbled computer or telephone transmissions, typographical or system errors and failures, faulty trans-missions, technical malfunctions, or otherwise. 

In the event of a dispute regarding the identity of the person submitting an entry, the entry will be deemed submitted by the authorized account holder at the time of entry. The authorized account holder is the natural person who is assigned to the account by Sponsor, the organization that is responsible for assigning accounts to customers. Potential winners may be required to show proof of being the authorized account holder. 

Any attempt by an entrant to obtain more than the stated number of entries by using multiple/different email addresses, identities, registrations, logins, and/ or any other methods, including, but not limited to, automated entry, will void that entrant’s entries and that entrant may be disqualified from the Sweepstakes. Multiple participants are not permitted to share the same email  

Sponsor will not verify receipt of entries for entrants. All entries submitted become the sole property of Sponsor. Sponsor reserves the right to disqualify those entries deemed to be inappropriate or in violation of this survey giveaway (as defined solely by Sponsor). 

Entries are void if they are incomplete, irregular, or submitted improperly. Personal information (if any) collected through the Entry Form will be used only for purposes of (i) selecting and contacting the winners, and (ii) as identified in the Privacy Policy. 

ODDS OF WINNING: The actual odds of winning will depend upon the actual number of total entries received for this survey giveaway, regardless of the means of entry. 

LIABILITY LIMITATION:  The Sponsor assumes no responsibility or liability for (a) lost, late, stolen, undelivered, inaccurate, incomplete, delayed, misdirected, damaged or garbled registrations, entries, URLs, or emails; (b) any incorrect or inaccurate entry information, or for any faulty or failed electronic data transmissions; (c) any unauthorized access to, or theft, destruction or alteration of entries or registrations at any point in the operation of this survey giveaway; (d) any technical malfunction, failure, error, omission, interruption, deletion, defect, delay in operation or communications line failure, regardless of cause, with regard to any equipment, systems, networks, lines, cable, satellites, servers, computers or providers utilized in any aspect of the operation of the survey giveaway; (e) inaccessibility or unavailability of the Internet or the Sponsor’s web site or any combination thereof or for computer hardware or software malfunctions, failures or difficulties, or other errors or difficulties of any kind whether human, mechanical, electronic, computer, network, typographical, printing or otherwise relating to or in connection with the survey giveaway, including, without limitation, errors or difficulties which may occur in connection with the administration of the survey giveaway, the processing of Entries, social networking posts, or registrations, the announcement of the prizes, or in any other  survey giveaway related materials; or (f) any injury or damage to participants or to any other person’s computer which may be related to or resulting from any attempt to participate in the survey giveaway. If, for any reason, the survey giveaway (or any part thereof) is not capable of running as planned for reasons which may include, without limitation, infection by computer virus, tampering, unauthorized intervention, fraud, technical failures, or any other causes which may corrupt or affect the administration, security, fairness, integrity or proper conduct of this survey giveaway, then the Sponsor reserve the right at their sole discretion to cancel, terminate, modify or suspend the survey giveaway in whole or in part. If terminated, the Sponsor will award the prizes from among all non-suspect, eligible Entries received for the survey giveaway up to the time of such action. 

RELEASES: All participants, as a condition of participation in this survey giveaway, agree to release, hold harmless and indemnify the Sponsor, its offers, directors, accountants, attorneys, and agents (“Released Parties”) from and against any and all liability, claims, damages, or actions of any kind whatsoever for injuries, damages, or losses to persons or property which may be sustained, in whole or in part, directly or indirectly, in connection with (i) participation in any aspect of the survey giveaway, (ii) the receipt, ownership or use of the prize awarded, including any travel associated with any prize, (iii) participant’s registration material on any related website, or (iv) any typographical or other error in these Rules.   

NO WARRANTIES: NEITHER SPONSOR NOR ANY OF THE RELEASED PARTIES HAVE MADE OR MAKE OR ARE RESPONSIBLE OR LIABLE FOR ANY WARRANTY, REPRESENTATION OR GUARANTEE, EXPRESS OR IMPLIED, RELATIVE TO THISSURVEY GIVEAWAY OR A PRIZE, INCLUDING BUT NOT LIMITED TO, ITS QUALITY OR FITNESS OR MERCHANTABILITY, AND ALL PRIZES ARE TENDERED TO ENTRANTS ON AN “AS IS” BASIS.  THERE ARE NO WARRANTIES REGARDING ANY PRIZE OR THE USE OF THE GIFT CARD. 

RANDOM DRAWING: Five (5) prize winner(s) will be randomly selected for the Survey giveaway to receive a $250 Digital Visa gift card. All decisions on all matters pertaining to the survey giveaway are final. The sponsor reserves the right to substitute a prize of equal or greater value. 

WINNER NOTIFICATION: Random selection of the potential prize winner will occur every day during the first two weeks of the survey giveaway Period from among all eligible entries received. Prize drawing will be conducted at Sponsor’s headquarters. The prize winner will be notified by e-mail and/or phone, in Sponsor’s discretion, within 5 days from the date of the winner selection. The winner will also be announced on the Harvey Performance Companies individual Social Media channels (LinkedIn, Instagram and Facebook). 

The designated prize winner will have 5 days from notification to claim the prize. Sponsor and its affiliates, subsidiaries, employees, agents, officers and directors, advertising and promotion agencies, and their respective officers, directors, employees, and their respective agents, will not be liable for unsuccessful efforts to notify a winner. 

The prize will be delivered via e-mail. No prize transfer, assignment or substitution by winner permitted. All federal, state and local taxes, fees and surcharges on prizes are the sole responsibility of the prize winner. If the prize winner declines the prize, fails to claim the prize, is unavailable for prize fulfillment, fails to abide by these Rules, or is ineligible, Sponsor may select an alternate winner from all remaining eligible entries. 

By entering this survey giveaway, each entrant gives his/her express permission to be contacted by the Sponsor by telephone, e-mail and/or postal mail for survey giveaway purposes. 

The winner, by acceptance of Prize, grants to Sponsor, and each of its respective designees, the right to publicize the winner’s name, address (city and state of residence), photograph, voice, statements and/or other likeness and prize information for advertising, promotional, trade and/or any other purpose in any media or format now known or hereafter devised, throughout the world, in perpetuity, without limitation and without further compensation, consideration, permission or notification, unless prohibited by law. 

THIRD PARTY & SOCIAL MEDIA:  This Sweepstakes is in no way sponsored by, endorsed by, associated with, or administered by Facebook, Instagram, Twitter, WhatsApp, Tumblr, Google, YouTube, WeChat, or WhatsApp (collectively “Social Media Sites”).  By entering this event, you agree to hold all Social Media Sites harmless for and from any potential claims you may have related to or arising out of this Sweepstakes. 

MISCELLANEOUS CONDITIONS: Sponsor reserves the right at its sole discretion to cancel, terminate, modify, or suspend the survey giveaway. 

Sponsor assumes no responsibility for any error, omission, interruption, deletion, defect, or delay in operation or transmission; communications line failure; theft or destruction of or unauthorized access to survey giveaway entries or entry forms; or alteration of entries or entry forms. Sponsor reserves the right to correct clerical or typographical errors in promotional materials or any materials related to the survey giveaway.  

WINNER NAME: To obtain the name of the winner, send a request to [email protected]  

CHOICE OF LAW AND JURISDICTION: This survey giveaway is governed by the internal substantive laws of Nevada, without regard to its conflicts of law provisions. 

Recycling Carbon Fiber: Importance & Process

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Carbon fiber is a woven cloth made of crystalline filaments of carbon cured with a polymer, which can be layered and shaped around a mold. It is an ideal material due to its impressive strength-to-weight ratio , meaning it’s very strong, but not heavy. Carbon fiber is five times lighter than steel with an equal elastic modulus, making it a better choice for many applications. Further, it is corrosion-resistant, non-flammable, and non-toxic, properties that make it an ideal material to use in aerospace, medical, construction, and military industries.

Machining Carbon Fiber

Machining Carbon Fiber can be challenging. The layered structure of the carbon fiber material can lead to delamination, uncut fibers, fiber tear-out, uneven tool wear, and poor surface finishes. Luckily, many cutting tool companies, like CoreHog, specially design tooling with different geometries that can help eliminate these manufacturing problems:

  • Straight Flute End Mills: Apply all the cutting forces radially, which helps prevent delamination.
  • Compression Cutters: Create opposite cutting forces, stabilizing material removal and preventing delamination, fiber pullout, and burrs along the surface.
  • Chipbreaker Cutters: Shear the fibers and shorten the chips, preventing fiber buildup around the cutter.
  • Diamond Cut End Mills: Utilize both left-hand and right-hand flutes to break up and shear through the fibers, ideal for roughing and profiling carbon fiber.

Explore CoreHog’s Wide Offering of Composite-Laminate Cutters, each specially engineered to cut difficult-to-machine laminate materials like carbon fiber.

Common Carbon Fiber Applications

In the aerospace industry, carbon fiber is used in plane structures to replace alloys, creating lighter planes and thus, reducing fuel consumption. Recreational sports also utilize carbon fiber to decrease weight. It is often seen as a leading material in skis, bikes, and tennis rackets, as the lighter weight can help improve performance. In professional sports leagues like Formula 1 and NASCAR, carbon fiber has grown in prevalence in recent years. Another advantageous quality of carbon fiber is its suitability in X-ray machines, allowing imaging to pass through without interruption, making it useful in many medical devices and implants.

Recycling Carbon Fiber

Why is Recycling Carbon Fiber Difficult?

Carbon fiber sheets require a significant amount of energy to produce. These large sheets are then cut down to the part size needed, and the excess material is often discarded, increasing waste production. This material is not biodegradable and is typically sent to a landfill where it will remain permanently. Further complicating recycling, carbon fiber is built to hold its shape and strength and cannot be melted down and reshaped like many plastics. When recycled, its properties are heavily degraded, rendering it useless for applications that experience heavy forces or loads.

How is Carbon Fiber Recycled?

Solvolysis

Solvolysis uses a chemical solvent to break down the polymer encasing the carbon fiber cloth. The waste carbon fiber is shredded into smaller pieces, increasing the surface area. The solvent, chosen based on the polymers used in the carbon fiber, breaks down the polymer chains, separating the carbon fiber from the polymer. Techniques like centrifugation are used to separate the substances. The carbon fiber can be further purified to restore its properties and then combined with virgin fibers to create new fabric or used by itself. This process enables the recovery of carbon fiber without sacrificing material properties.

Pyrolysis

Pyrolytic utilizes heat to break down the polymer encasing the carbon fiber cloth. The waste carbon fiber is shredded into smaller pieces and then heated in a controlled environment with limited or no oxygen. At high temperatures, the polymer undergoes thermal decomposition, producing gases, vapors, and char. The gases and vapors can be used as an energy source or further processed, while the char, which is carbon fiber and any original additives, is purified to ensure mechanical properties are maintained. The resulting carbon fiber can be used alone or combined with virgin fibers. Pyrolysis is effective for high-quality fiber recovery and energy recovery from gas byproducts.

Carbon Fiber Considerations

As we innovate with new technology, it is important to consider its impact on our planet. Carbon fiber is an amazing material that can improve many aspects across industries; however, the waste generated is not going anywhere but a landfill. Many companies are investing in producing high-quality recycled carbon fiber. With a shift in focus to designing closed-loop systems for composite materials, the future looks bright.

Multi-Axis Finisher Q&A

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What is a Multi-Axis Finisher?

A tool that uses an extremely large radius to increase finishing performance in two different ways, depending on the needs of the machinist. Either the Multi-Axis Finisher will provide a better surface finish than a traditional Ball End Mill in the same amount of time, or will provide the same surface finish in far less time than a traditional Ball End Mill. A middle ground with improved surface finish and reduced cycle time is also easily achievable.

What Are Other Names for Multi-Axis Finishers?

Multi-Axis Finishers are oftentimes referred to as Barrel Cutters or Conical Barrel Mills or Circle Segment Cutters, among many others.

What Are the Different Forms of Multi-Axis Finishers, and How Do They Differ?

There are several different forms of Multi-Axis Finishers, including Lens, Taper, Oval, and Barrel. With a Lens Form, there’s a large radius on the end of the tool that’s in line with the tool axis. Taper Form, in contrast, has three tangential radii and a large radius defined at a specific angle relative to the tool axis. An Oval Form has two tangential radii, offering additional angle flexibility, while a Barrel Form has a large radius on the OD of the tool.

The most significant benefit is oftentimes observed utilizing a Taper Form Multi-Axis Finisher, as the radius of this tool can become vastly large on this form, while the others are more limited. However, this great benefit also comes with the least amount of flexibility in terms of approach to a workpiece.

What Are the Benefits of a Multi-Axis Finisher?

There are two clear benefits to using a Multi-Axis Finisher, compared to a Ball End Mill: Increased surface finish, and reduced cycle time (Or most likely both, concurrently).

What is a Benefit Multiple?

Helical Solutions is the industry’s premier manufacturer of Multi-Axis Finishers, and the Benefit Multiple is a significant reason why. Helical specifies the theoretical benefit that can be seen with its Multi-Axis Finishers, providing machinists direct insight into the gains that can be realized with these tools.

Benefit Multiple refers to the Cusp Height, correlated directly with the theoretically-achievable surface finish. Assuming the same cusp height from a Ball End Mill to a Multi-Axis Finisher, the Benefit Multiple relates to the time savings that could be seen in a machinists’ toolpath. For example, a Benefit Multiple of 4 would result in a toolpath ¼ as long as for a Ball End Mill of the same diameter. The stepover pass-to-pass would be 400% as much as a Ball End Mill to keep the same cusp.

When Should I Not Use a Multi-Axis Finisher?

Multi-Axis Finishers are best applied to wide-open surface areas; or large, smooth contours rather than small features or tight areas. Application of these tools will always be on a case-by-case basis. For help with your specific application, contact Helical Solutions Technical Support at 866-543-5422.

How Can I Get the Most Out of My Multi-Axis Finisher?

Multi-Axis finishers are best utilized when working further towards the OD of the tool. Tapered Form Multi-Axis Finishers are the most obvious choice for this, as its nose radius is small and has the least amount of efficiency. Similarly to a ball end mill, working near the center will have limited cutting ability, while the OD of the tool will see the full surface footage of the programmed RPM.

Taper Form Multi-Axis Finishers should be used when tilted at the specified taper angle. Oval Form Multi-Axis Finishers should be used towards the OD. Lens Form Multi-Axis Finishers should be tilted to avoid working on-center.

Lens Form Multi-Axis Finishers Look Like a High Feed End Mill. Can I Use it That Way?


Yes. However, there are differences in the form, and while a Lens Form Multi-Axis Finisher could theoretically be used as a High Feed End Mill, the two tools are not interchangeable.  A High Feed End Mill would not be the best choice for Multi-Axis Finishing, nor would a Lens Form Multi-Axis Finisher be our first recommendation for feed milling.

Do I need special software to program Multi-Axis Finishers?

Yes. A number of years ago, there were only a few CAM software packages that supported the programming of these specific forms. Nowadays, most CAM software providers have some degree of support for this method. Two of the first CAM software offerings to support this were MasterCAM and Hypermill, though many additional options exist today.

Why haven’t I heard of Multi-Axis Finishers Until Now?

In the grand scheme of things, Multi-Axis Finishers provide a very new approach to finishing, having been developed within the last handful of years.  Similar to High Efficiency Milling, these tools offer a new technique to approach your workpiece, offering increased efficiency and reduced cycle times.  Compared to the history of milling, modern tool manufacturing and CAM software have only just become able to program these unique forms.  Multi-axis finishers are positioned to revolutionize the world of finishing.

For more information on Multi-Axis Finishers, visit Multi-Axis Finishers: The Key to Amazing Surface Finish.

Multi-Axis Finishers: The Key to Amazing Surface Finish

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A Key to Improving Surface Finish

In today’s Manufacturing Industry, part finish and machining efficiency are key to a successful machine shop. It’s no surprise, therefore, that the popularity Multi-Axis Finishers has never been greater. Helical Solutions is a leader in the manufacturing of Multi-Axis Finishers, and its customers utilize this impressive tool when faced with extremely high surface finish requirements, oftentimes swapping out a traditional Ball End Mill to dramatically improve finish while minimizing cycle times.

Multi-Axis Finisher Basic Principles

A Multi-Axis Finisher can be easily recognized by its large radius included in the profile of the tool. With a larger radius, a far greater stepover can be used pass-to-pass while keeping the same cusp height as a Ball End Mill. This decreases the cycle time by a known value called the Benefit Multiple.

A Multi-Axis Finisher with a Benefit Multiple of 8 will reduce the cycle time to 1/8 of the cycle time for a Ball End Mill of the same shank diameter – an 87.5% time savings! If a Multi-Axis Finisher is used with the same pass-to-pass stepover as a Ball End Mill, the finish will be drastically improved due to exponentially smaller cusp heights. Most situations allow both reduced cycle time and improved surface finish to be achieved.

The images below show the comparison of a ball end mill to an Oval Shape Multi-Axis Finisher with a benefit multiple of 4.

Due to their large radii, Multi-Axis Finishers are best suited for wide open, flowing, and somewhat flat surfaces. Smaller spaces, especially tight corners, will generally not see as much benefit from these tools due to limited use of the major radius.

Multi-Axis Finisher Tool Selection

The Manufacturing Industry’s leader in Multi-Axis Finishers, Helical Solutions offers 3 distinct profiles, each fully stocked and available to ship the day of purchase.

Oval Form Multi-Axis Finishers

The oval form includes 2 tangential radii and offers the most versatility in smaller spaces where a slightly varied approach angle is required, such as impellers or fan blades.

Taper Form Multi-Axis Finishers

The taper form includes 3 tangential radii and a taper angle. It allows for the largest radius, and therefore greatest potential improvement of finish and reduction of cycle time. They are best used where a specific approach angle is needed and where maximum performance gain is desired.

Lens Form Multi-Axis Finishers

The lens form includes 2 tangential radii on the end of the tool and is used for work mostly on the face of a part. Tilt angles of approximately 5 degrees are recommended for these tools to avoid working on-center.

Programming Multi-Axis Finishers

Programming Multi-Axis Finishers requires some additional consideration compared to a typical end mill. Luckily, many modern CAM packages offer support for these unique profiles, including many of Helical’s CAM partners. Each software has their own name for these toolpaths, so reach out to your CAM or Helical sales rep to find how you can program yours!

For more information on Multi-Axis Finishers, and to learn if this advantageous tool is right for you, read our Multi-Axis Finishers Q&A.