Either a fly cutter or face mill can be used to machine the face of a plate, what’s the difference between fly cutters and face mills?
1. Fly cutters tend to be cheaper than face mills. Large face mills and their inserts are expensive.
2. Face mills use multiple inserts, which allows removing more materials at higher speeds, a fly cutter only uses one insert, which is not as fast as face milling but offers a more uniform and smooth surface.
3. The fly cutter is a better choice for the skim cut with large width and special profile requires the tool to possess, face mill is suitable for heavy removal.
4. A fly cutter will run and give good results on less weighty, less powerful machines, but with a lower metal removal rate. A face mill requires more power and more rigidity than a fly cutter of the same diameter.
5. Face mills are more ideal in rigidity, indexability of inserts without disturbing effective cutter diameter or tool length offset, and depth-of-cut capability.
6. A fly cutter will produce a very flat surface with proper setup, the cutting edge can cover a large surface in one pass, a face will produce a more ridged surface as its cutting edges are not at the same height.