A face milling cutter is used to machine flat metal surfaces with high speed, smooth finish, and accuracy in CNC and workshop milling operations.

How Face Milling Works

A face milling tool spins in the machine and the cutting edges touch the workpiece from above. As the tool turns, each insert edge cuts a small amount of metal. Many cutting edges working together remove a large amount of material in one pass. The result is a flat and even surface. This type of milling is called face milling because the surface created is on the face of the workpiece. Multiple cutting edges help distribute load and improve surface finish.

The way this cutter works makes it ideal for two things:

1. Heavy material removal: It can remove a lot of metal quickly.
2. Fine finishing: It produces smooth and flat surfaces without extra work.

For these reasons, face milling is often the first machining step after rough cutting or forging.

Side and Face Milling Cutter

A side and face milling cutter is a tool that has cutting teeth on both its side and around the edge. That means it can cut slots, deep cuts, and flat surfaces using the same tool. Side and face cutters are especially useful when you need to mill a narrow flat feature on both the side and face of a workpiece. They are common in traditional milling machines and help reduce the number of tool changes.

Both face milling cutters and side and face milling cutters are important tools in workshop tool kits. The main difference is that the side and face cutter also cuts on the side, while the face milling cutter mainly works on the flat top surface.

Types of Face Milling Cutter

Face milling cutters come in many types depending on size, material, and purpose. Most common types seen in machines today include:

• Indexable Face Mills: These use replaceable carbide inserts. Inserts can be rotated or replaced when worn, giving longer life and less downtime.
• High Speed Steel (HSS) Cutters: Made from hardened steel, these cutters are cheaper and used for general milling on softer metals.
• PCD and Coated Cutters: Tools with polycrystalline diamond or coated surfaces give longer life and work well on abrasive materials.
• Carbide Face Mills: These are very strong and work fast on hard metals and heavy cuts. They are often used in CNC machining.

The size of a face milling cutter depends on the machine and the workpiece. Small cutters might be 20–50 mm in diameter for light jobs, while bigger cutters can be 100–200 mm or more for large flat surfaces.

Face Mill Cutter Sizes

When deciding on size, you should consider the job you want to do:

• Small Dimension Work: Small diameter cutters are used for light finishing and narrow parts.
• Medium Flats: Medium sizes like 50 mm–100 mm cover most everyday workshop milling jobs.
• Large Surface Milling: Larger cutters (100 mm or more) are used in CNC vertical milling machines to cover big workpieces quickly.

The size you choose also affects the rate of material removal. Bigger tools can remove more metal per pass, but they require more power and stable machines. Smaller machines should not use very large face milling cutters because it can overload the machine and reduce finish quality.

Choosing the Right Face Mill

To select a good face milling cutter, consider these points:

• Material You Are Milling: Harder materials need stronger cutters and better inserts.
• Machine Power: Big cutters need more power and rigidity from the machine.
• Surface Finish Required: Finer finish needs good quality inserts and correct parameters.
• Insert Cost: Indexable inserts cost more upfront but save money long term.

Choosing the right tool ensures less wear, better surface finish, and faster production.

Benefits of Face Milling Cutters

There are many advantages when you use the right face milling cutter:

• Fast Material Removal: Multiple edges cut metal quickly and evenly.
• Better Surface Finish: High quality cutters leave a smooth flat finish.
• Replaceable Inserts: You save money because only inserts are changed, not the whole cutter body.
• Versatile Uses: They can work on steel, aluminium, plastic, cast iron and other materials.

All these benefits make face milling cutters ideal for workshops and factories that need fast and accurate milling.

Frequently Asked Questions 

What is a face milling cutter used for?
It is used to make flat surfaces and remove material quickly on top of a workpiece.

What is the difference between a side and face milling cutter and a face milling cutter?
Side and face cutters cut on both side and face, while face milling cutters mainly cut the flat top surface.

Which size face mill should I choose?
Choose based on your machine power and size of the surface you want to mill — small for fine jobs, large for big flats.

Can face milling cutters be used on CNC machines?
Yes, indexable face mills are ideal for CNC vertical and horizontal milling machines