Warco mill

Warco mill

Type	Machine Tools
Manufacturer	Warco
Model	Unknown

We have a Warco mill, which requires a induction to use, this tool is quite new and more documentation will be added here later

Tooling

Selection of the correct tool for a given operation is important. While with some experience you will start to get a good feel for what is required to cut different materials, this is intended as an outline to begin with.

End mills

End mills are the 'standard' tool for milling metal. They generally have different geometries, materials and numbers of teeth, but are general purpose cutters for almost any operation - but not necessarily the ideal tool for all of them. They are usually used for slotting, shoulder cuts, profiling and

Some endmills are designed to also do a limited amount of plunge cutting, while others aren't. If the cutting edge joins in the centre at the bottom of the cutter, it can be used for plunge cutting, though using a pilot drill is still advisable.

End mill selection

Two Flute Square mills

Two Flute endmills and slotting drills are generally ideal for cutting grooves or slots in aluminium and other soft materials, along with mild steel and cast iron. Generally, don't try using them for stainless, unless they are specifically designed for it, as stainless is much harder to cut. They can also be used for general milling of aluminium, particularly given the main limiting factor of the mill is rigidity, not necessarily the tooling.

Three Flute Square mills

Three flute endmills are generally used for cutting grooves and slots in steel, and general milling of aluminium and softer materials. Carbide is advised for most grades of stainless, as it tends to work harden.

Four Flute Square mills

Four flute endmills are ideal for cutting steels, and harder materials, but can 'gum up' in softer materials, due to having less chip clearance, and generally a different geometry of tooth.

Finishing mills

Finishing endmills generally have more, smooth teeth than general purpose square ones. They are generally used to create a cleaner finish on sides that have cut, but should not be used to take deep cuts.

Roughing mills

Roughing endmills have varying numbers of teeth, but have a 'thread-like' pattern on the teeth, to assist in material removal. They are generally used for deeper cuts in steel, and to perform mass-material removal. They will not leave a particularly clean surface, and you will need to finish the cut with another endmill to get a good surface finish.

A note on slot drills

For the purposes of this page, I am treating slot drills as a type of 2 flute endmill, but they can also cut their own holes. I am not distinguishing between them and standard endmills that can plunge cut, as there are now sufficient different geometries of 'endmill' that it somewhat overcomplicates matters.