The Differences Between Face Milling and End Milling

What is Face Milling?

Face milling is when we cut the top of a flat part. We use a big, wide tool with many small cutting bits on it. The tool spins and moves across the top of the part. This makes the top nice and flat.

Face milling is good for making parts with flat tops. We use face milling on big, flat parts. The tool sits at a right angle to the part.

When we face mill, we take off a little bit of metal from a big area. This makes the part smooth and flat. can help you with face milling jobs.

What is End Milling?

End milling uses a skinny tool with cutting edges on the sides and bottom. This tool can cut in many ways. It can cut down, to the side, or make fancy shapes.

End milling is good for making:

• Slots
• Pockets
• Grooves
• Fancy shapes

The end mill tool has flutes (cutting edges) that curl around it. These flutes help cut the metal and move chips away. For making more complex parts, our team uses CNC pocket milling with end mills.

Big Differences Between Face Milling and End Milling

Let’s see how these two types of milling are not the same:

When to Use Face Milling

Use face milling when you need:

• Very flat and smooth tops
• To make engine parts that must be flat
• To work with soft metals like aluminum
• To take off a little bit of material from a big area
• To make mold bases that need to be very flat

Face milling is great for making flat parts in car engines. It can make parts flat within 0.05 mm, which is very, very flat!

When to Use End Milling

Use end milling when you need:

• To make slots or holes
• To cut fancy shapes
• To make 3D parts with curves
• To cut hard metals like steel
• To work on small parts

End milling is used to make parts for airplanes, like turbine blades. These parts have complex shapes that face milling can’t make. Our 5 axis machining service uses end mills for the most complex parts.

Tools for Face Milling

Face milling tools are big and flat on the bottom. They have many small cutting bits called inserts. When one insert gets dull, we can change just that one.

The face mill has:

• Many cutting inserts
• A wide body
• A flat bottom

These tools last a long time because we can change the small inserts. This saves money because we don’t need to buy a whole new tool.

Tools for End Milling

End mills come in many shapes and sizes:

• Ball nose end mills (round tip)
• Square end mills (flat tip)
• Tapered end mills (pointy)
• Roughing end mills (wavy edges)

End mills have different numbers of flutes:

• 2-4 flutes for soft metals
• 6+ flutes for hard metals

The helix angle (how the flutes twist) helps get chips out. High helix angles work best for aluminum.

Materials and Speed

The type of metal changes how we mill:

Face Milling Works Best On:

• Aluminum (very fast and smooth)
• Brass
• Plastic
• Mild steel

End Milling Works Best On:

• Hard steel
• Stainless steel
• Titanium
• Complex shapes in any metal

Face milling can remove material 30% faster than end milling when working on flat surfaces. But end milling is needed for complex shapes.

Surface Finish

The surface finish is how smooth the part is after cutting.

Face Milling:

• Makes very smooth surfaces (Ra 0.8–3.2 μm)
• Leaves fewer tool marks
• Makes very flat surfaces

End Milling:

• Makes rougher surfaces (Ra 3.2–12.5 μm)
• May leave more tool marks
• May need more work to get smooth

For the best finish with end mills, we use 3D CNC milling with ball nose end mills.

Real-Life Examples

Face Milling Example:

In car factories, they use face mills to make engine blocks. These blocks must be very flat where the head goes. Face milling makes them flat within 0.05 mm.

End Milling Example:

In airplane factories, they use end mills to make turbine blades. These blades have fancy curves that need 4-flute carbide end mills.

Common Mistakes to Avoid

Face Milling Mistakes:

• Cutting too deep at once
• Not using enough coolant
• Using dull inserts
• Going too fast

End Milling Mistakes:

• Using the wrong number of flutes
• Cutting too deep
• Using a tool that’s too long (it will bend)
• Going the wrong direction around the part

How to Pick the Right One

To choose between face milling and end milling, ask:

1. Do I need a flat surface? → Face milling
2. Do I need slots or fancy shapes? → End milling
3. Am I working with soft metal? → Face milling works great
4. Do I need to cut deep? → End milling can go deeper
5. Do I need a very smooth finish? → Face milling is smoother

Important Tips for Success

Face Milling Tips:

• Use wiper inserts for mirror finishes
• Cover 60–75% of the cutter width in each pass
• Use plenty of coolant
• Start with low speeds and work up

End Milling Tips:

• Use high-helix end mills (45°) for aluminum
• Use shorter end mills when possible (less bending)
• Go slower for hard metals
• Use more flutes for hard metals, fewer for soft

Questions People Ask

Summary

Face milling is best for:

• Flat surfaces
• Fast material removal
• Smooth finishes
• Soft metals

End milling is best for:

• Complex shapes
• Slots and pockets
• Deep cuts
• Hard metals

Both types of milling are important. The best choice depends on what you’re making. For complex parts, you might need both types!

Remember: match the right tool to the job. This will save time, money, and make better parts.