Discover the key differences between face milling vs. end milling, including their processes, applications, tool types, and advantages. Learn which method is best for your machining needs.
Milling is a fundamental process in the world of machining where components are shaped and finished with high levels of precision. Despite that, not every operation is performed with a milling machine. They are the most common and rarely confused methods: face milling and end milling. While the removal of materials is achieved similarly by both, tools and techniques can differ dramatically.
In this article, we will show you how to go about each of those steps, list their main differences, and tell you what will be the most appropriate method for your next machining job.
Face Milling, Definition
In face milling, the cutting action takes place in the end corners of the milling cutter due to a combination of cutting actions. It is used for building flat surfaces (faces) of a workpiece. The tool rotates perpendicular to the surface machined and removes material with the cutter teeth at each pass.
Key Steps in Face Milling
- The surface is perpendicular to the spindle to which the cutter is mounted, and rotating.
- The workpiece is then in contact with the face of the cutter.
- The face is covered by the cutter moving side to side (X or Y direction, the entire face.
- For large surfaces with fine finishes in multiple passes may be needed.
Common Face Milling Cutters:
- Shell mills
- Fly cutters
- Face mills with indexable inserts
Applications
- Creating flat surfaces
- Surface finishing
- Large area stock removal
- When working on wide, broad surfaces, face milling is very efficient.
How to Define End Milling?
A versatile machining process that is performed with the end and sides of the tool is end milling. The tool is made in a vertical orientation, and tools are removing material synchronously in both the circumference and bottom cuts.
Key Steps in End Milling:
End mills are available in different geometrical profiles and flute designs to aid precision work and precision detailing, and in harder-to-reach areas.
- The end mill rotates around a vertical axis.
- The speed at which horizontal cutting occurs and vertical plunge may even be exactly the same.
- Used for complex profiles, slots, holes, and contours.
End Milling’s Edge: Precision and Versatility
It offers unmatched flexibility. You can use it to:
- Cut deep slots
- Create pockets and contours
- Drill and shape edges
- Machine both 2D and 3D profiles
It’s highly popular in mold making, die manufacturing, and high-precision industries such as aerospace and medical devices.
The Applications of End Milling
End milling can be applied to some specific use cases, such as:
- Keyway cutting
- Engraving and surface patterning
- Chamfering and beveling
- Making gears and splines
- 3D surface sculpting in die cavities
- End milling is an indispensable operation for controlling depth, width, and angle.
Face Milling Process
Face milling is a milling process that utilizes the cutting edges on the face (or end) of the tool mainly to take away material from the surface of a workpiece. The tool is generally held at right angles to the surface that is being worked.
How It Works:
- A large-diameter cutter (frequently having several inserts or teeth) turns at high speed.
- The bottom edge of the cutter, the face, cuts away material in sweeping, lateral strokes over the top of the workpiece.
- The operation produces a flat, smooth surface with an even finish.
Best Used For:
- Flattening or squaring large surfaces
- Rapid material removal over large areas
- High-quality surface finishing
Typical Tools:
Shell mills, face mills, fly cutters
End Milling Process
End milling employs a cutting tool that takes away material with both its bottom (end) and side edges. The cutter is normally vertical and will plunge directly into the material or cut laterally.
How It Works:
- An end mill is rotated on a vertical axis and can travel in any direction (up/down or side-to-side).
- It can drill into the workpiece, then shift horizontally to form features like slots, holes, pockets, or contours.
- This operation is ideal for making accurate, detailed, and varied cuts, particularly in 2D and 3D shapes.
Best for:
- Slotting, pocketing, profiling, engraving
- Machining internal and delicate details
- Tight tolerance or complex components
Common Tools:
Flat end mills, ball nose end mills, bull nose end mills, tapered end mills
Face Milling vs. End Milling
While both face and end milling use rotating cutting tools, their primary functions and cutting actions differ.
What’s the Main Difference? It’s All in the Cut
| Feature | Face Milling | End Milling |
| Cutting Action | On the face (bottom edge of the tool) | On the side and tip of the tool |
| Surface Type | Flat horizontal surfaces | Slots, pockets, profiles, and contours |
| Tool Orientation | Perpendicular to the surface | Vertical with axial and radial cutting |
| Tool Movement | Mostly lateral passes | Plunging and side cuts |
| Typical Tools | Face mills, fly cutters | End mills (flat, ball, bull-nose) |
Why Does This Matter to You?
Face or end milling is a choice that impacts your production efficiency and quality directly. Employing the right process reduces the number of tool passes, enhances surface smoothness, and prolongs the life of cutting tools. It also ensures accurate dimensions and tolerances. Conversely, the wrong process choice can result in inferior finishes, vibration (chatter), and tool damage, costing valuable time and raising production costs.
Selecting the Proper Milling: Face or End?
Not all milling techniques are suitable for all tasks. The choice will be based on your workpiece geometry, detail required, and surface finish type needed. Face milling is optimal for flat, broad surfaces, whereas end milling is optimal for more detailed, multi-directional cutting operations. Considering these aspects guarantees maximum results and machining effectiveness.
When to Use Face Milling
Use face milling when your objective is to produce a clean, flat surface over a large area. It’s the first choice for rapid material removal and high-quality surface finishes. Suitable for operations such as surface flattening, squaring parts, or preparing blanks for subsequent machining. It’s best used on large, flat workpieces.
When to Use End Milling
End milling is the preferred way to machine fine shapes, slender slots, and internal details. It’s ideal for 3D profiling, plunge cuts, or when tight corners need to be machined. This technique provides high accuracy and versatility and is best used for parts needing precise or
sophisticated geometries.
End Milling: Deeper than the Surface
End milling isn’t limited to basic cuts. It’s an adaptable, very versatile method that can adapt to part complexity.
End Mill Types: A Tool for Every Task
There is a specific use for each type in precision machining, enabling you to perform a broad variety of tasks with precision.
- End mills are available in numerous shapes and configurations:
- Flat End Mills: For flat surfaces and sharp corners.
- Ball Nose End Mills: For 3D contours and rounded edges.
- Bull Nose End Mills: Combination of flat and ball ends.
- Corner Radius End Mills: Minimize stress and enhance tool life.
- Roughing End Mills: Ideal for fast stock removal.
- Tapered End Mills: Suitable for mold cavities and sloping surfaces.
End Milling Strategies: Upcut vs. Downcut
- Upcut Milling (conventional):
- Draws chips up
- Most suitable for removing high volumes of material
- Can leave more coarse finishes
- Downcut Milling (climb):
- Forces chips down
- Creates cleaner finishes
- Needs a more stringent setup, but is less consumable for tool wear
- Selecting the proper approach influences finish quality, heat, and tool wear.
Pro Tip: Selecting the Correct End Mill
- Material: Utilize carbide tools for hardened steels, HSS for less hard metals.
- Coating: TiN or TiAlN coatings enhance heat resistance.
- Flute Count: The more flutes = smoother finish; the fewer flutes = improved chip clearance.
- Shank Size: Size of the collet or holder for the lowest runout.
- Helix Angle: Influences chip flow and cutting force—increases the angle to lower vibration.
Face Milling vs. End Milling: The Advantages and Limitations
Recognizing the relative advantages and limitations of each method guarantees you the best selection for performance and part quality.
Face Milling Pros:
- Fast and efficient surface finishing
- Ideal for large, flat surfaces
- Smooth finishes with multiple inserts
Face Milling Cons:
- Limited to surface work
- Not suitable for deep or narrow cuts
- For heavy-duty applications, they require larger machines.
End Milling Pros
- Highly versatile for complex geometries
- Ideal for Pockets, Slots, and Profiles.
- Ideal for precision work
End Milling Cons
- Slower for large surface areas
- Tool breakage is possible in aggressive cuts
- Requires the appropriate tool geometry selection.
A Handy Cheat Sheet:
| Goal | Best Method |
| Flat surface finishing | Face Milling |
| Slotting or pocketing | End Milling |
| Complex contours | End Milling |
| Fast material removal | Face Milling |
| Fine detail or engraving | End Milling |
Conclusion
Face milling and end milling in the machining world are two very important operations. Each of them serves a different purpose, uses a different tool, and achieves a different outcome. Face milling is an excellent choice for flat, big surface finishing, while end milling is best for detail work, unique shapes, and precision cuts.
Learning about these differences enables you to machine faster, and produces parts with better quality, less waste, and at a lower cost.
If you are creating a precision prototype or making the final product for some other reason, choosing just the right milling method simply makes a difference, so you need to use it and know how to utilize it.
FAQs – Face Milling vs End Milling
Q1: Can I use end mills to face mill?
Technically, yes, but it’s inefficient. However, face mills can be single-use on small areas, and dedicated face mills are faster and produce a better finish on large areas.
Q2: What is the best pocket milling tool?
The straight edges and flat bottoms of flat-end mills are ideal for cutting pockets.
Q3: Can we use face mills on CNC Machines?
Yes, face milling is a common CNC operation, especially in the case of surface finishing.
Q4: What’s the typical depth of cut in face milling?
Depending on the material and tool, between 0.5–3 mm is common for most materials.
Q5: Which process produces better finishes?
In face milling, multiple cutting edges work simultaneously and consequently. Here we can produce a smoother finish than by single cutting edges.
