What are face milling and vertical milling : their differences and applications?

Milling is a critical process in manufacturing, and there are generally two common milling techniques: face milling and end milling. Engineers frequently compare these two techniques, as they have different uses and varying advantages and limitations when manufacturing precision parts. Therefore, it is crucial for CNC engineers to understand the differences between these two methods to achieve optimal results for the precision parts required in the various applications they are responsible for. In this article, we will discuss what face milling and end milling are, their characteristics, applications, advantages, and disadvantages, and provide a comparative analysis to help you make the right choice.

What is face milling?

Face milling is a common milling machining process that uses a rotating cutting tool to remove material from the surface of a workpiece, creating a flat surface. The cutting edge of the face milling cutter is located on its periphery and surface. This process is primarily used to create flat, smooth surfaces or to rapidly machine large surfaces. Unlike vertical milling, face milling is typically performed on a horizontal milling machine.

If you require precision parts with a planar design, face milling using end mills, face cutters, or fly cutters can create top-quality planar surfaces; however, it only provides a medium-quality surface finish. Furthermore, face milling can be used to machine various metals and plastics, primarily for smoothing raised edges and surfaces during part machining, as well as machining cavities and parallel surfaces. Face milling typically uses large-diameter tools, including ball-end, chamfer, and fillet cutters.

What is end milling?

End milling is a process that uses an end mill to cut from multiple directions (such as the sides and bottom) to create features such as grooves, contours, and recesses. The cutting force mainly comes from the cutting edge on the side of the tool. It is typically used to machine cavities, shoulders, slots, pockets, and contours. In addition, it can also enable unique part designs, including cutting different shapes, creating cavities, engraving, and contouring.

Using end milling means you can perform contour machining, grooving, keyway machining, countersinking, and other irregular shape machining on precision parts. Compared to face milling, end milling doesn’t produce the best surface finish, typically between 0.29 µm and 0.95 µm. However, it still offers a good appearance.

Four key differences between face milling and end milling

Comparison items	Face milling	End milling
Main cutting edge	Indexable inserts on the bottom of the cutter head	Peripheral and end cutting edges of the cutting tool
Typical uses	Milling large-area planes	Cavity opening, milling groove, sidewall, 3D curved surface
Cutting tool shape	Large diameter disc type	Cylindrical, with various blade shapes
Chip removal direction	radial ejection	Chips are discharged upward along the spiral groove and require cooling.

How face milling and vertical milling work together

In the manufacturing of precision parts, end milling and face milling are typically combined in multiple processes to balance production efficiency and precision. When manufacturing precision parts with planar designs, end milling is usually performed first to quickly remove excess material, establish a flat and stable reference surface, and ensure consistent part thickness. This is crucial for datum control and repeatable fixture assembly. Once these reference surfaces are established, face milling is then used to machine the fine features of the part, such as cavities, slots, contours, shoulders, and complex profiles, to meet tighter tolerances and controllable surface finishes.

Using both processes simultaneously can separate bulk material removal from feature-level machining. This combined approach can minimize cumulative dimensional errors caused by tool wear, improve surface integrity, and ensure that the machining of precision features is performed relative to a precise and reliable reference plane.

Industry applications of face milling and end milling , and the parts that can be manufactured.

Face milling and end milling are applicable to a wide range of industries, but they produce parts with different characteristics. Face milling is widely used for machining large flat surfaces. It is commonly used in the automotive, aerospace, and manufacturing industries, where large parts require precision and high-quality surface finishes. End milling, on the other hand, is typically used for applications requiring precise cutting, such as the production of molds, dies, and complex machine parts. It is particularly useful in industries requiring complex designs, such as electronics, medical devices, and aerospace.

Industry Applications	Typical Parts Manufactured
Automotive, aerospace, heavy equipment, industrial machinery, energy, mold and die	Engine blocks, cylinder heads, gearbox housings, machine bases, structural plates, mold bases
Aerospace, medical devices, electronics, automotive, mold and die, precision engineering	Brackets, pockets and slots, impellers, turbine components, medical implants, electronic housings
Construction equipment, shipbuilding, rail transit, defense	Large panels, frames, mounting surfaces, chassis components
Robotics, automation, consumer products, optics	Precision arms, sensor mounts, enclosures, complex contoured parts
Oil and gas, power generation	Valve bodies, pump housings, flanges, pressure plates
Aerospace and high-precision manufacturing	Mold cavities, dies, airfoil profiles, complex 3D surfaces

Comparison of the advantages and disadvantages of face milling and end milling

Face milling and end milling each have their own advantages and limitations based on their technological characteristics. A key feature of face milling is its large cutting surface, and the face milling cutter has multiple cutting teeth, allowing a large amount of material to be removed in a single pass. This makes face milling extremely efficient for tasks requiring the machining of large surfaces.

Another key feature of end mills is their versatility; their properties allow for both horizontal and vertical cutting, making them suitable for a wide range of applications. End mills have a smaller diameter than face mills, enabling more precise cuts and access to narrower spaces.

Face milling		End milling
advantage	shortcoming	advantage	shortcoming
Highly efficient material removal: Face milling is very fast, and a large amount of material can be removed in one operation.High-quality surface finish: This process produces a smooth, flat surface, making it ideal for many industrial applications.	Limited to flat surfaces: Face milling is designed to create flat surfaces and therefore cannot be used for more complex or precise shapes.	Precision: End milling is extremely precise and can create complex shapes and detailed features.	Slower material removal rate: Unlike face milling, end milling is slower because it removes less material.
Low cutting force: The cutting force is evenly distributed on the surface, reducing the stress on the cutting tool and the workpiece.	Large machines are required: Due to the size of the face milling cutter and the nature of the operation, this process is usually carried out on a large horizontal milling machine, which may not be available in small workshops.	Versatility: The wide variety of shapes and sizes of end mills makes this process suitable for a wide range of applications.	Higher cutting forces: End milling typically requires higher cutting forces, which leads to more severe wear on the cutting tools.
		Suitable for vertical surfaces: End milling can easily machine vertical surfaces or create grooves and slots.

How do I determine whether to use face milling or end milling for my project?

To manufacture parts that meet the requirements of the drawings, several factors typically determine the best machining process for your project. These factors generally include the specific requirements of the project, the type of material to be machined, the complexity of the design, and the desired surface finish. While each machining method has its advantages, understanding the differences in their end results is crucial.

If your parts are large and have extensive planar designs, requiring rapid removal of significant amounts of material from the planes, face milling is a common choice. This machining process is well-suited for mass production of planar design parts. However, if you are designing and manufacturing precision parts with highly complex designs, then vertical milling is your preferred technology during manufacturing. Vertical milling offers versatility and flexibility and is compatible with vertical milling machines. Therefore, the type of machine tool used by the manufacturer will also determine the process chosen when manufacturing the parts.

Tips for determining whether face milling or end milling is more suitable for your part manufacturing project

When determining whether to use a face milling cutter or an end mill for a part project you are responsible for, you can use the following techniques to judge whether it is appropriate.

High surface finish is required

If the primary goal is to achieve a very flat and smooth surface over a large area, then a face mill is usually a better choice.

Does the part have complex feature design?

If the part design has many slots, grooves, contours, and complex 3D shapes, use an end mill, as it can cut with the sides and ends.

Does the part have a large planar design?

Face cutters are ideal for machining larger, flatter surfaces. End mills are more adaptable to various workpiece sizes and can machine smaller or narrower areas.

roughing of a plane

When your parts are large and you need to quickly machine an uneven original surface into a flat reference surface, choose face milling.

Large-area precision processing

When a large, high-quality flat surface is required, such as a machine tool bed or a precision instrument mounting surface, please choose face milling.

Features of a 90-degree angle

The part design features an end face that is perpendicular to its adjacent surface and at a 90-degree angle. Please select end face milling.

Grooving

Choose vertical milling when your part design requires slots of varying depths to be machined along the inside or edges of the part.

Miniature Milling

Choose vertical milling when your part design requires machining inner pockets or cavities inside the part.

Shaping

Choose vertical milling when you need to machine the outer contours of parts such as cams or blades, or complex three-dimensional surfaces.

Drilling and boring

In some cases, end mills can also be used for simple drilling and boring.

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in conclusion

Understanding the difference between face milling and end milling is crucial for choosing the right technology for the custom parts projects you are responsible for sourcing. This is because the correct method must be chosen based on the part design to manufacture a product that meets the requirements.

Face milling is generally well-suited for large, flat surfaces due to its speed and efficiency, while end milling offers superior precision and versatility, making it suitable for more complex shapes and smaller components. By considering the characteristics, applications, advantages, and disadvantages of each method, you can choose the appropriate milling technique for your specific needs. Whether using face milling for rapid material removal or end milling for complex designs, both methods play an indispensable role in the machining process.

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