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This section provides an overview for fly cutters as well as their applications and principles. Also, please take a look at the list of 8 fly cutter manufacturers and their company rankings. Here are the top-ranked fly cutter companies as of December, 2024: 1.Amtek Tool & Supply, 2.Kennametal Inc., 3.NIKKEN KOSAKUSHO WORKS, LTD.-.
Table of Contents
A fly cutter, also called a front face fly cutter or face mill, is a tool that is primarily attached to a milling machine and rotates a cutting tool to cut the workpiece on the table.
Compared to other cutting tools, fly cutters have a wider cutting area at a time, so they can efficiently machine a wide flat surface or side surface by cutting it all at once. Since cutting a flat surface is often the first step in various workpieces, fly cutters are almost indispensable cutting tools for metalworking.
Fly cutters are used for machining surfaces such as flat surfaces, sides, and stepped surfaces due to the large area that can be machined at a time, and they can also be used for machining with high surface accuracy.
Generally, due to the large diameter of the blade, multiple inserts are evenly distributed around the circumference of the blade.
Since the number of inserts, outer diameter, and even the angle of blade attachment differs depending on the type of fly cutter, it is often necessary to use multiple fly cutters together, even when machining flat surfaces.
The larger the diameter of the cutter, the more area it can cut. At the same time, the greater the load on the machine, so a machine tool with more power is required.
The larger the number of inserts, the smaller the load applied to each insert and the greater the cutting volume per revolution. Therefore, a cutter with a larger diameter and more inserts has higher machining efficiency. On the other hand, a large number of cutters with a large diameter and a greater number of blades will have high machining efficiency, but care must be taken when roughing out a substantial number of chips.
There are also two types of blade installation angles, one is the insertion angle when the cutter is viewed from the side (axial rake angle) and the other is the insertion angle when viewed from the back (radial rake angle), depending on the type and application. For example, for soft metals such as aluminum and copper, select a cutter with a large radial rake angle. For hard, crispy metals such as cast iron, select a cutter with a small radial rake angle to emphasize chip evacuation.
Side cutters are used when milling large quantities of long, deep grooves, especially when using horizontal milling machines.
Side cutters can be used to perform groove milling operations such as open grooves, closed grooves, gang slitting, and butt cutting.
Side cutters are available in a variety of diameters and thicknesses, which can be used to achieve the desired groove length and depth.
When using side cutters, the cutter size, pitch, and position must be controlled so that at least one cutting edge always bites into the cutting area. It is also recommended that cutting with side cutters be performed by gown cutting.
Cutting conditions for fly cutters include cutting speed, feed rate, and outer cutter diameter, which are set according to the cutter material used and the material to be cut.
The feed rate is set relatively low when priority is given to extending cutter life, when the workpiece is hard, when rough machining is performed, or when wear progresses rapidly.
On the other hand, if the material has good machinability, or if a smooth finished surface is required for finish cutting or precision finishing, the feed rate is set relatively high.
The feed rate per blade (calculated from the feed rate, number of cutter blades, and number of cutter revolutions) is set relatively high when the shape of the workpiece cannot be stably fixed, when the workpiece is too thin to be stably fixed, or when a smooth finished surface is required such as finish cutting or precision finishing. When a smooth finish surface is required, when the cutting edge causes chipping and the feed rate does not fall below the minimum feed rate even if the feed rate is lowered, or when deep grooves are to be cut, the feed rate is set relatively low.
On the other hand, when heavy cutting is performed on a rigidly mounted workpiece, when a material with good machinability is used, when the surface to be machined is intermittent, when wear on the flank surface increases rapidly, or when the machine is bivy, the feed rate is set relatively high.
*Including some distributors, etc.
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Kennametal, Inc. is an American manufacturer and distributor of engineering tools and materials that was established in 1938 in Pittsburgh, Pennsylvania. The company primarily produces mining and metalworking tools such as solid carbide cutters and indexable inserts. They also offer components as well as materials, including metal powders, drill bits, tungsten-based alloys, and carbide rods and blanks. These are commonly used in construction, transportation, and energy production, as well as in surface and underground mining operations. Kennametal, Inc. operates internationally with several subsidiaries of its own, including Sintec Keramik GmbH, Stellite Holdings Ltd, and Conforma Clad Inc.
Paul Horn GmbH - HORN has been a manufacturer of grooving tools and precision grooving technology since 1969, headquartered in Luxembourg, Europe. The company deals in cutting tools for milling processes, turning operations, broaching, gear cutting, and more, and also offers tooling systems, modular and quick-change tool holders, and custom solutions for applications that require precision cutting. For example, one of the products known as Supermini is designed for machining complex contours with small diameters and for various other applications in the automotive, chemicals, aerospace, medical, and tool and mold-making industries.
NIKKEN KOSAKUSHO WORKS, LTD.- was founded in 1958 and is a manufacturer of machine tool attachments and industrial tools based in Daito, Osaka, Japan. The company manufactures various products such as NC tooling system, CNC rotary table, carbide PF radical mill reamer, conventional milling chuck, and tool ID management system. The products are distributed to various countries such as United Kingdom, France, Italy, Germany, and Sweden. The company has participated in various exhibitions, including Mechatronics Technology Japan (MECT) 2023.
Tungaloy Corporation, established in 1934 and headquartered in Fukushima, Japan, is a manufacturer of metal cutting tools and industrial products. The company's product line includes turning, milling, and drilling tools with various dimensions. It also provides various resources such as machining calculator tools, tool navigators, and insert selection guides. Its products are designed to maximize the amount of metal being removed from parts. The company holds several certifications, including ISO 9001 and OHSAS 18001. It serves various industries, including automobile, construction, aerospace, and medical.
The Company operates diverse businesses, ranging from nonferrous metals and other fundamental materials to cemented cardide tools/metalworking solutions, the manufacturing of semiconductor-related and electronic components/materials, resource recycling, and renewable energy power generation. In each business, the Company holds the No.1 position in production volume, sales volume, etc.
Sandvik Coromant is based in Sandviken, Sweden, and is a manufacturer of metal-cutting tools and services that was founded in 1942 as a subsidiary of Sandvik Group. The company produces tools and inserts used for fabrication operations such as milling, turning, and drilling. These include ball and roller screws, linear actuators, and digital tooling systems or software. The company is ISO 9001, ISO 14001, and ISO 45001 certified. It primarily serves clients in the aerospace, medical device production, and energy sectors.
Amtek Tool and Supply, Inc. based in Madison Heights, MI. Amtetk is an online super market for tools, supplies, and other hardware for individual, professional, and corporate customers. Product types include milling, threading, and turning devices, tooling systems, saws, broaching and deburring bits, cutting tool blanks and spares, abrasives, power tools, hand tools, safety equipment, measuring devices, lubrication, sanitation supplies, storage, pneumatics, shipping supplies, transmissions, and various other hardware and shipping supplies. Amtek’s online storefront offers precise filters to help find exact products to meet customer needs.
Gesswein Co, Inc., established in 1914 and headquartered in Bridgeport, Connecticut, is a distributor of jewelers' tools and supplies. The company offers a wide range of products, including additive manufacturing tools, abrasives, bench tools, burs & drills, casting tools, cleaning tools, dust collection tools, engraving tools, power tools, and more. These products are utilized by professionals in the jewelry and metalworking industries for precision work. Gesswein Co, Inc. also provides various services, such as operations review, product sampling, account maintenance, quality control, and price matching.
Ranking as of December 2024
Derivation Method| Rank | Company | Click Share |
|---|---|---|
| 1 | Amtek Tool & Supply |
27.3%
|
| 2 | Kennametal Inc. |
18.2%
|
| 3 | NIKKEN KOSAKUSHO WORKS, LTD.- |
13.6%
|
| 4 | Sandvik Coromant |
13.6%
|
| 5 | Hartmetall-Werkzeugfabrik Paul Horn GmbH |
9.1%
|
| 6 | TUNGALOY CORPORATION |
9.1%
|
| 7 | Gesswein Co, Inc. |
4.5%
|
| 8 | Mitsubishi Materials Corporation |
4.5%
|
Derivation Method
The ranking is calculated based on the click share within the fly cutter page as of December 2024. Click share is defined as the total number of clicks for all companies during the period divided by the number of clicks for each company.Number of Employees
Newly Established Company
Company with a History
*Including some distributors, etc.
*Including some distributors, etc.
| Country | Number of Companies | Share (%) |
|---|---|---|
|
United States of America
|
1 | 33.3% |
|
Germany
|
1 | 33.3% |
|
Japan
|
1 | 33.3% |
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