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Fusion 360 milling12/15/2023 ![]() ![]() ![]() This is a very inefficient way of machining a flat surface like this. We can reduce the size of these cusps by reducing the size of the step over or the passes. If we use this tool to cut through the material, again, we will be left with stock that has the geometry of the tool, i.e., the radius or the half ball on the end.Īs you can see, when we have multiple passes using the Ball Nose Mill, we’re left with the material in between these, which are called cusps. ![]() This is where we now move on to our Ball Nose mill. For these, a Flat End Mill is not ideal to use. However, many parts have more complex, curved surfaces. In this case, we can use a flat end mill to finish our parts to final form. This is perfect if the geometry that we’re trying to machine has a flat bottom and straight-sided walls. If we look at our Flat End Mill, for example, when we cut away material using this, we’re going to be left with stock that has a flat bottom and straight-sided walls to match the tool’s geometry. So why would we use one of these types of tools over another? It really comes down to a combination of the type of geometry that we’re trying to machine and the stage of the process that we’re at. To keep things simple, we’ll focus on our Flat End Mill and our Ball Nose Mill in this video. Now there is a type of tool that lies somewhere between these two, which can be called a Bull Nose Mill or a Tip Radius End Mill, which has a partly flat bottom with a radius just around the edges. Ball Nose Mills have a radius, a hemisphere, or half of a ball (which is where it gets its name from) to give it a rounded end instead. Flat End Mills get their name from having a flat bottom all the way across, which then comes at 90 degrees onto our sides. In this video, we show two of the more commonly used milling tools: a Flat End Mill and a Ball Nose Mill. ![]()
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