Form milling, with its ability to produce complex surfaces and contours in a single pass, has become an indispensable process in industries such as aerospace, automotive, mold and die, and medical devices. This article will delve into the core elements of form milling, including process principles, tool types, material selection, advantages, and limitations. Drawing on practical application examples, this article will help you better understand the value and applicable scenarios of this highly efficient machining method.
What is form milling
Form milling is a milling method that uses a forming tool to create a specific contour or surface in a single pass. The shape of the tool’s cutting edge directly determines the resulting contour, making form milling particularly suitable for machining complex geometries such as concave and convex surfaces, tooth profiles, notches, fillets, and chamfers.
Compared to conventional plane milling or face milling, form milling offers the advantage of completing complex shapes in a single pass, reducing the need for multiple setups and tool changes, significantly improving production efficiency and dimensional consistency. This makes it an indispensable tool in precision manufacturing.
The Importance Of Molding And Machining In The Manufacturing Industry
High-precision shape control : The precision control of cutting tools is achieved, and the actual fine-grain precision control is achieved.
High efficiency machining : Reduced multi-step cutting, increased production speed.
Additional structure manufacturing : Can be processed in other ways to create a more realistic curved surface or shaped cavity.
Consistency given weight availability : conformity, quantity, production, shape conformity requirements, zero requirements.
How does form milling work
The core principle of form milling is to use a tool geometry that precisely matches the final contour of the workpiece to create the desired curved surface, contour, or cavity in metal or other materials through the rotation of a milling cutter. During the machining process, the tool shape directly determines the geometric accuracy and surface profile of the finished product, eliminating the need for complex multi-axis path compensation, allowing complex structures to be formed in a single operation.
Integrated with a CNC control system, the tool path, feed rate, and cutting depth of form m
illing can be precisely controlled, ensuring a stable and highly repeatable machining process. Compared to end milling and contour milling, form milling offers greater efficiency and precision when machining specialized surfaces such as arcs, grooves, tooth shapes, and fillets, making it particularly suitable for mass production and high-consistency production.
Marking Process Steps
Selection Of Swords
Factors such as foundation work shape, material hardness, surface quality requirements, etc. are used to select molded iron molds, such as concave swords, convex swords, square swords, circular swords, etc.
Cutting tool materials commonly used include high speed steel (HSS), hard quality alloy (carbide), gold-plated steel, etc., ensuring cutting strength and durability.
Construction Equipment
Use high-precision tools or jigs for fixing work, avoid movement of the worker’s position or vibration during the cutting process.
Thin walls, long shapes, etc., easily changeable, multi-point support, vacuum suction, etc., with enhanced properties.
CNC Editing (G Daiwa)
The 3D model for the construction work, the shape of the tool, the number of copies, and the processing sequence.
Setting main machine speed, running speed, cutting depth, etc., and ensuring machining accuracy according to the cutting tool command.
cutting Process
Suitable for tool setting, fixed path diameter cutting work, primary forming or step cutting.
Use coolant or body cooling to reduce cutting heat and prevent tool polishing and construction changes.
Precision Processing Yogi
After finishing cutting, the work progresses to remove the hair, remove the light, etc., and process the surface.
Uses three measuring machines (CMMs), such as cross-sections, measuring dimensions, shape accuracy, and ensuring compliance with paper requirements.
The difference between form milling and other milling methods
| Silvering method | Special point | Applicable costume |
| Form Milling | Sword shape, standard pattern, surface matching, primary molding process | Wheel shape, arc surface, curved surface zero |
| End Milling | Cutting the end face of the tool, cutting the mating surface of the mating tank | Plane, direct tank, slope |
| Profile Milling | 2 lines / 3 lines running sword, suitability strength | Curved line, circular line processing |
| Angular Milling | Cutting angle surface or slope | slanting tank, slanting surface |
| Slot Milling | Various processing tank types | T-type tank, straight tank, round tank |
| Face Milling | High efficiency machining plane | Large plane surface machining |
What types of tools are used for form milling?
In form milling, the tool is a key factor in determining part accuracy, machining efficiency, and surface quality. Form milling tools can be divided into seven major categories, each with unique cutting characteristics and applications. Choosing the right tool not only allows you to form complex contours in one go, reducing subsequent machining steps, but also significantly reduces production costs and increases overall productivity.
Today’s manufacturing industries include aeronautics, automobiles, medical equipment, energy equipment, precision molding, etc., as well as molding and cutting tools, which can be used to process curved surfaces, uneven structures, and special molded parts. Below our general information, commonly seen seven types of molded silver cutting tools, analysis of the product’s structural characteristics, application scene, and special limitations :
1. Concave Iron Sword
Concave iron-like sword blade shape with inner concave arc surface, commonly used processing zero outer convex curved surface, similar circular shape, spherical convex pattern, convex circular shape, etc.
Special Points :
Primary running sword ready-to-form convex curved surface with optical smoothness
Guaranteed accuracy sum consistency
For regular inspection of items with high requirements for matching beauty and surface quality
: mechanical parts, mold external mold processing, precision equipment external parts.
2. Convex Iron Sword
Convex curved surface on the outer side of the sword blade, concave curved surface on the inner surface as required for processing, mold-shaped cavity, arced surface on the inner wall of the connecting pipe, etc.
Special Points :
Reduced number of swords
Functional machining: deep and smooth concave passages
for regular use : model- shaped cavity, liquid head cavity, machine parts concave cavity.
3. Inclined Square Iron Sword
When used, the processing angle (R angle) or inclination angle (C angle) can be used to reduce force concentration, increase safety, and reduce lifespan.
Special Points :
At the same time, the strength of the structure and the external quality
Frequently used for transportation
: aviation equipment delivery, medical equipment maintenance, electricity consumption.
4. Double-Horned & Double-Horned Lron Sword
South side bevel processing for double angle iron swords, primary forming and double side slopes for double angle iron swords.
Special Points :
High double-sided sword processing efficiency, low running sword order
Precise processing of V-shaped tank, commonly known as slope,
for common use : molding surface, machinery components, engineering tools.
5. Spiral Iron Sword
Used for high-precision internal and external screw machining, especially for large diameter screw machining or hard machining materials.
Special Points :
Processable spiral of arbitrary diameter
High quality screw thread, regular use of screws for escape and breakage
: aviation equipment, large machinery screw openings, power container openings.
6. T-Shaped Tank & Running Iron Sword
T-shaped tank First-forming T-shaped cut-faced tank, suitable for production with standard model.
Special Points :
T-type tank machining determination, reduced multi-dimensional positioning difference
for production
: desk floor workbench , tool bottom plate, user’s wheel.
7. Preformed Molding Tool
Netode specific zero items, how many structured tools, available primary equipment, completed various cutting tasks.
Special Points :
Significantly reduces tool changes and machine downtime.
Highly targeted and fast production cycles.
Common applications: High-volume production and specialized equipment parts processing.
Key Factors For Selecting Swords
During actual production, the following factors are considered when selecting molding and cutting tools:
What shape is the shape of the zero item ? Determined sword ring shape
Construction materials ——Influences, sword materials, and selection of construction materials
Processing quantity ——impact and tool durability requirements
Accuracy given surface quality —determined knife edge design given number of machine shapes
Desk ability : Assurance of swords and tools
| sword type | Machining shape special expedition | habitual behavior | excellence | localized |
| concave iron sword | External convex curved surface | Aerospace, models, machine manufacturing | High surface quality, good flow consistency | Mismatched deep cisterna stenosis |
| convex iron sword | Inner concave curved surface | Model-shaped cavity, energy equipment, zero train parts | Deep concave surface machining setting | High requirements for cutting tool sharpness |
| Inclined square iron sword | R corner / C corner passing | Aviation, medical, consumer electronics | Concentration of power in the fall, sightseeing | Unlawful processing curve |
| Southern horn iron sword | southern slope | Molds, tools, machinery components | High accuracy, good activity | Low efficiency double-horned sword |
| double-horned iron sword | Named V-type tank | Molds, fittings, and components | Primary forming double slope, high efficiency | Fixed shape, different applicability |
| Spiral iron sword | Inner and outer spiral | Aviation, machinery, power vessels | High quality screw thread, woven process | increase the amount |
| T type tank iron knife | T-shaped cut tank | Manufacture of desk floors, utensils, and equipment | High localization accuracy | Limited T tank processing |
| racing iron sword | Togata | Car, mechanical operation | Large amount of driving performance | Demand machine combination |
| Regular cutlery | special wheelhouse | Equipment for use, zero quantity | High efficiency, strong strength | Narimoto High School, design cycle length |
What are the common materials used for form milling tools
In form milling, the choice of tool material is a key factor affecting machining accuracy, tool life, and production efficiency. Different materials have their own strengths and weaknesses in terms of hardness, wear resistance, heat resistance, and toughness. Therefore, in production practice, the most suitable tool material is selected based on the characteristics of the material being machined, cutting speed, processing batch size, and surface quality requirements. Commonly used form milling tool materials include high-speed steel, cemented carbide, ceramics, powder metallurgy alloys, diamond tools, and various coated tools.
The following is a detailed explanation of the machine’s performance features and its application :
1. High Speed Steel (HSS)
Performance features : good porosity, strong anti-collision ability, high cutting power, easy grinding and forming.
Applicable equipment : Processed low-quality steel, iron alloy, iron, etc. or medium hardness metal, which may also be suitable for sword-shaped and small-scale production.
Disadvantages : Low completion, reversible heavy polishing, but low heat resistance and abrasion resistance, high speed cutting.
2. Hard Alloy
Performance features : high hardness, wear resistance and heat resistance, acceptable cutting temperature of 800–1000℃.
Applicable equipment : Machining non-ferrous steel, steel alloy, steel-based heat-resistant alloy and other cutting materials, high-speed high-precision molding and machining.
Advantages : high processing efficiency, long service life, low mechanical strength, sensitive to heat.
3. Pottery
Performance features : Extremely high hardness and high temperature resistance (can withstand over 1200℃), combined dry type high speed cutting.
Applicable equipment : Precision processing and semi-precision processing of iron, high hardness steel and heat resistant alloy.
Disadvantages : Strong wear resistance, but high brittleness, and large cutting amount due to improper joint cutting.
4. Powder Metallurgy Alloy
Performance features : combination of high-speed steel, hardness and abrasion resistance of alloy, fine structure uniformity, and high blade strength.
Suitable for : Low hardness metals during machining, suitable for production of low-hardness metals, and when there is a certain requirement for long tool life.
Disadvantages : Good binding performance, but poor heat resistance, hard alloy, limited high speed cutting surface.
5. Kanaseishi Sword Tools
Performance features : Hardness is the highest in nature (HV 8000–10000), friction coefficient is low, processed surface light quality is high.
Applicable equipment : non-metallic and non-metallic materials such as processed iron, copper, composite materials, ceramics, plastics, etc.
Advantages : Long service life, high processing accuracy, but high cost, and non-conforming alloy base material.
6. Curling Tools (TiN, TiAlN, etc.)
Performance features : Abrasion resistant, heat resistant, low friction thin film on the surface of the tool on the base, long tool life and machining performance.
Applicable equipment : High-speed mass processing of various metal materials, especially those with high hardness or easily sticky materials.
Excellent points : Performance proposal written by Xuan, however, the swords are high quality, and the second grade is heavy and durable.
How to Choose the Right Form Milling Tool
In form milling, tool selection not only determines machining efficiency but also directly impacts part precision, surface quality, and overall production costs. Faced with diverse materials, varying profiles, and diverse production demands, selecting the right tool is crucial for ensuring machining stability and cost-effectiveness. A comprehensive consideration of material properties, tool structure, coating technology, and machining parameters is crucial to achieving the optimal balance between quality and cost.
First Step: Material Compatibility
The performance of the workpiece material is the key factor in selecting the tool. When processing iron, iron, etc., high-speed steel or metal cutting tools are recommended, and the cutting blade has excellent surface optical quality, Alloy knives, with abrasion resistance and heat resistance, materials such as high hardness steel, firework steel, and ash mouth iron, porcelain knives and curved hard alloy knives that can be fired, retain cutting performance even at high temperatures. Depending on the material and the quality of the tool, the long tool life will be reduced and the tool renewal rate will be reduced.
Second Step: Designing The Shape Of The Sword
The process of molding, cutting, and refining the curved surface requires a high level of assembly in terms of the shape and shape of the tool. When machining a large curvature surface, concave or convex shaped iron can provide high machining efficiency, the demand for light smoothing angle is zero, the use of inverted angle round edge is possible, thin-walled or easy to change shape work selection, low cutting force design, less vibration and change shape winding. Special mold surface, fixed molding tool ability, primary molding, height and weight processing, consistency and accuracy.
Third Stage: Durability And Durability
The protection and performance enhancement effect of the key when molding and cutting the tool under the knife. TiN is suitable for the majority of machining situations, capable of low friction and effective, TiAlN is suitable for high-speed, high-temperature cutting, and can be extended for a long period of time when machining hard materials, DLC It is easy to process iron, iron, etc. when the material is sticky and can be used to reduce the formation of small lumps. Correctly selected, the mechanical strength of the cutting layer is indeterminate, the cutting quality is reduced, the number of blades is reduced, the number of blades is reduced, and the production time is reduced.
4th Stage: Processing Number Yoseimoto
Machining speed, flow rate, cutting depth, etc. directly affect tool selection. Hard quality alloys suitable for high speed machining, ceramic or metal cutting tools, and high speed steel or steel and hard quality alloys suitable for low speed heavy cutting. High precision or zero tolerance during production, high hardness for preferential selection, finely polished tools with consistent size, and high volume production, long demand life, easy polishability and excellent balance between the originals. Combining the material, shape, layer and processing number, ensuring the talent and processing quality at the same time to achieve the best results.
How to Perform Quality Control in Form Milling
Quality control in form milling relies on precise measurement, strict tolerance management, and surface quality inspection to ensure that every workpiece meets design requirements and industry standards. High-precision measuring equipment, stable machining parameters, and comprehensive inspection processes enable comprehensive control from micron-level dimensions to surface roughness.
1. How To Play
During molding and machining, it is the first step to ensure quality.
CMM three-pronged measuring machine : It is possible to perform high-precision measuring work in three different spaces, and can also be used for additional curved surfaces and different shapes.
Optical measurement system : use non-contact type intense light drawing or image measurement, actual rapid measurement, avoid contact type head construction construction surface damage.
Current play : During the processing process, the actual time play, and the time deviation adjustment can be made.
2. Tolerance Management
Forming and machining process and ±0.005mm extremely precise tolerance control.
Early stage of engineering : Precise CNC processing, cutting tool adjustment, and precision cutting path diameter.
Processing process : The use of constant temperature processing environment reduces the effect of heating and cooling.
Post-engineering period : Utilize precision tools with heavy localization capabilities, ensuring consistency throughout production.
3.Surface Roughness And Light Quality Requirements
The required dimensions are met without molding and machining, and the surface quality is in full demand.
Ra 1.6 μm or less : Suitable for multiple processes, reliable installation performance.
Ra 0.8 μm or even lower : Commonly used in areas requiring high light quality, such as model cavities and medical cases.
Techniques : high speed precision machining for the clasp, improved cutting fluid for the knife, and surface polishing for the small knife.
4. Quality Control Consolidation Strategy
high-quality molding and machining equipment + engineering improvement + operation training .
Production Advancement Inquiry (FAI)
The total amount of industrial extraction and the total combination
100% measuring amount
Strengthening operator’s quality awareness training
Advantages and Disadvantages of Form Milling
The advantages of form milling primarily include the ability to produce complex shapes in a single pass, high precision and consistency, compatibility with a wide range of materials, and cost-effectiveness in mass production. Disadvantages include time-consuming initial setup and programming, rapid tool wear, limitations in machining large workpieces, and the need for secondary finishing operations in some cases.
Detailed explanation of the lower direction :
Excellence
The first cutting tool is ready to be processed, the shape
of the needle can be formed, and the cutting tool can be used for cutting, the first cutting can be formed, the curved surface of the needle can be formed, and the curved surface can be customized, reducing the cutting time and greatly increasing the efficiency.
The high precision and consistency,
it is possible to reduce the weight and increase the number of tools, and to easily maintain the turning precision and surface consistency, and to control the fine tolerances.
Available in a variety of materials
, ready-to-process iron, colored metals such as iron, high-strength materials such as non-ferrous steel, iron alloys, and other processed plastic materials .
The production efficiency is high
in the first half after the finished tool design and testing, the processing time is short, the tool utilization rate is high, and the adjustment period is fixed.
Inferiority
Early equipment supply, wear and tear,
tool demand, zero-item shape regulation, number setting, CNC production progress, impact new product introduction speed.
Tool polishing:
easy cutting blades and uneven bearing force, intensive polishing when processing hard materials are available, periodic repairs or replacements.
Large-scale work processing is limited
to work that exceeds the production floor process or cutting tool cover.
Possible demand for secondary precision processing,
high light efficiency or accuracy requirements, after molding and cutting, demand for grinding, polishing, etc.
Common Applications of Form Milling
Common applications for form milling include gear manufacturing, aerospace and automotive parts processing, mold making, medical device parts, custom prototype machining, and decorative and functional contouring. These fields all require high precision, complex contouring, and stable mass production. Different applications have different requirements for tool design, machining parameters, and material compatibility. Choosing the right process can significantly improve production efficiency and product quality.
| area for use | Special processing expedition | typical material | engineering excellence |
| racing production | Precision machining machine turning factory, guaranteeing accuracy and movement efficiency | Alloy steel, red bean steel, unsteel steel | Primary molding high precision shape, reduced polishing process |
| Aviation Aerospace Vehicle Zero Parts | Compound curved surface Japanese loop structure, loop quantification design | Brass alloy, steel alloy, steel alloy | High strength material processing ability, high accuracy and consistency |
| Mock making | Precision curved surface, mold cavity and special features | Tool steel, hard alloy | Primary running sword molding, reduced electric discharge processing or manual repair |
| Zero medical equipment | Microscopic zero particles, high surface quality | Steel, steel alloys, medical plastics | High-precision hair pricking processing, matching medical record standard |
| Fixed prototype processing | Multiple shapes, rapid transit | Brass alloys, process plastics, composite materials | Short training period, fast acquisition available. |
| Decoration and functional processing | A combination of beauty and specific abilities | Iron, iron, iron, plastic | Primary molding of glazed glaze, high surface quality |
Safety Precautions Section
Molding metal cutting is used during high-precision manufacturing, but its machining process and high-speed turning tools, the use of coolant generates a large amount of chips, so this guarantees machining efficiency at the same time, and must be carefully monitored to ensure operational safety and environmental protection. This will ensure the safety of operators and the flexibility of production and production for the company.
- Operator safety protection
Personal protective equipment (PPE) : Operators need protective eyeglasses, split-proof gloves, anti-slip safety shoes, safety equipment, etc. Flying debris or heat-cut debris creates damage.
Desk floor protection system : all-enclosed protection system, emergency stop option and safety reciprocal system, prevention of non-certified personnel operation.
Safety training : Periodic maintenance of safety operations such as tool replacement, equipment adjustment, and routine security procedures.
- How the coolant works
Use environmentally friendly decomposable coolant, reduce harmful chemical components and environmental impact.
Periodically draining and renewing the coolant, preventing bacteria growth and performance decline.
Before the liquid is processed, the components can be recycled and reused.
- Chip collection and fee management
of metal scraps and material quality classification ( iron, steel, iron, etc.), direct entry into re-healing environment.
The oil-containing cutting waste is de-oiled, the height is recovered, and the liquid is discharged.
Establishment of a standard procedure for the release of waste, evacuation environment, and scorching winds.
Molded Metal Future
Adjunct intelligent manufacturing and green manufacturing development, automatic molding and cutting process, high efficiency, low consumption process. A futuristic competition, which is different in terms of machining accuracy and speed, and in addition, it is possible to combine technology and increase the amount of expansion.
- Automation And AI improvement
Automatic converter system (ATC) provides equipment, manpower and up-down costs , reduces artificial drought, and has become a 24-minute timeless human transformation industry.
AI calculation improves the cutting path , automatically adjusts the number of basic machining processes, increases the cutting path diameter, increases the tool life, shortens the machining cycle.
- New Type Of Cutting Tool Material
Nano-coating technologies (such as TiAlN and AlCrN) improve wear resistance and heat dissipation, enabling higher cutting speeds.
New carbide, ceramic, and polycrystalline diamond (PCD) cutting tools further break through machining bottlenecks in high-hardness and high-heat-resistant materials.
- Mixed Manufacturing Technology (CNC + bulk material manufacturing)
CNC pre-machining allows for advanced material production (3D stamping), rapid molding, and reduces material waste.
The mixing desk floor can be made of the same flat platform, and the material is integrated into an integrated process, and the delivery period is shorter and shorter.
FAQs
What Is Form Milling?
Form Milling Is A Machining Process Where I Use Specially Shaped Cutters To Produce Complex Contours, Curves, Or Profiles In A Single Pass. By Employing CNC Equipment, I Can Achieve Geometric Accuracy Within ±0.005 Mm And Surface Roughness As Low As Ra 1.6 µm. This Method Is Ideal For Parts Requiring Precision Shapes, Such As Gears, Molds, Or Turbine Blades, And It Eliminates The Need For Multiple Setups Or Secondary Operations.
How Does Form Milling Work?
Form Milling Works By Using A Cutter Whose Profile Matches The Desired Geometry On The Workpiece. I Begin By Selecting The Cutter, Securely Clamping The Workpiece, And Programming CNC Toolpaths. Cutting Parameters—Such As 60–120 M/Min Cutting Speed And 0.05–0.2 Mm/Tooth Feed—Are Calculated For The Material. The Cutter Engages Gradually To Reduce Tool Wear, Then Completes The Profile In One Or Several Passes, Achieving High Repeatability And Dimensional Consistency Across Multiple Parts.
What Is The Purpose Of Form Milling?
The Purpose Of Form Milling Is To Manufacturing Complex Profiles Accurately And Efficiently. In My Practice, This Process Is Used To Create Consistent Curvatures, Grooves, Or Angular Features That Would Be Time-Consuming With Standard End Milling. It Improves Productivity By Reducing Multi-Tool Operations To A Single Setup, Lowers Cumulative Tolerances, And Ensures ±0.005 Mm Accuracy. This Makes It Essential For Aerospace, Medical, And Automotive Components Where Reliability And Interchangeability Are Critical.
What Are The Different Types Of Form Milling Cutters?
Form Milling Cutters Include Concave Cutters For Inside Curves, Convex Cutters For Outside Curves, And Corner Rounding Cutters For Edge Radii. I Also Use Single-Angle And Double-Angle Cutters For Chamfers, T-Slot Cutters For Slotting, Gear Cutters For Tooth Profiles, And Custom Tools For Unique Geometries. Cutter Selection Depends On Part Design, Required Tolerances, And Material—For Example, Using Carbide-Tipped Tools For Hardened Steel To Maintain Sharpness And Dimensional Stability Over Long Runs.
What Materials Can Be Machined With Form Milling?
I Use Form Milling On Metals Such As Aluminum, Stainless Steel, Titanium, And Nickel Alloys, As Well As Engineering Plastics Like PEEK And Delrin. Composites And Non-Ferrous Materials Are Also Common. Each Material Requires Adjusted Cutting Speeds—Aluminum At 150–300 M/Min, Stainless Steel At 50–90 M/Min—to Optimize Tool Life And Surface Finish. This Versatility Makes Form Milling Suitable For High-Mix, Low-Volume Projects Or Mass Production Across Multiple Industries.
Conclusion
Molding and machining are highly efficient and precise processing methods, which is one of the most indispensable core technologies in the modern manufacturing industry. There is no need to worry about the production efficiency of the production method, the pursuit of higher zero-item precision and consistency, and the ability to mold and cut the metal. Due to the continuous use of automation and new materials, the potential of industrial engineering is maintained, and more and more companies are forced to exit during the fierce market competition.
