Tool Diameter

Theoretical Physics and Mechanics of Tool Rigidity

The mechanical behavior of an end mill under cutting loads is modeled using classical structural beam mechanics. Specifically, a milling tool clamped in a tool holder is analyzed as a cantilever beam subjected to a transverse point load at its free end (representing the radial cutting forces acting on the tool tip).

1.1 The Deflection Equation

When a cutting force $F$ (in Newtons) is applied radially to the tip of the tool, the lateral displacement or deflection $y$ (in millimeters) is expressed by the classic beam deflection formula:

Machining Physics and Strategy Selection

The selection of tool diameter directly governs the cutting kinematics, material removal capabilities, and surface generation physics in Fusion 360.

2.1 Slotting vs. Pocketing

The radial engagement ($a_e$) profile determines how the tool experiences deflection forces:

Tool Material Selection Guidelines

The physical properties of the tool material dictate how the tool responds to deflection forces and thermal stress. The table below outlines the mechanical characteristics of primary end mill materials: