Face Mills: The Exacta-Set PCD Milling System

When it comes to precision machining and surface finishing, face mills play an important role in industries like aerospace, automotive, and other precision engineering sectors. Whether machining aluminium, composite materials, or hardened metals, choosing the right face mills can significantly impact machining productivity, tool life, and surface quality.

At Exactaform, we’ve taken PCD face milling technology to the next level with our Exacta-Set PCD Milling System, a cartridge-style face mill designed for unmatched durability, flexibility, and precision. Here, we’ll explore what makes a great face mill, the advantages of the Exacta-Set, and how it transforms existing machining performance.

What Are Face Mills?

A face mill is a type of milling cutter designed for cutting flat surfaces. Unlike end mills, which cut with the tip, face mills use multiple cutting edges around the periphery of the tool, making them ideal for high-speed surface machining, large material removal, and precision finishing.

Face mills come in various geometries and are made out of different material depending on your machining purpose. PCD (Polycrystalline Diamond) face mills are seen as the best on the market for machining aluminium, composites, and non-ferrous materials.

Introducing the Exacta-Set PCD Face Milling System

After gaining over 45 years experience in the PCD tooling market, and years of industry research and development, Exactaform created the Exacta-Set PCD Milling System, a cartridge-style PCD face mill engineered for superior stability, performance, and longevity. Unlike traditional monoblock designs, the Exacta-Set allows full axial adjustment, ensuring the best possible surface finish and extended tool life.

Key Features of the Exacta-Set Face Mill

• Cartridge-Style Design – Unlike solid-body tools, the Exacta-Set allows precise axial adjustments, giving manufacturers the flexibility to fine-tune cutting parameters for maximum performance.
• Aluminium Cutter Body – Reduces spindle wear, absorbs crash shock, and enhances acceleration/deceleration, making it lightweight yet robust for high-speed milling.
• Chip Deflection Technology – Built into the cutter body, reducing cartridge costs and improving chip evacuation for cleaner cutting operations.
• Five Cartridge Geometries – Customisable with multiple nose preparations and wiper configurations, ensuring adaptability to various face milling challenges.
• Ground & Laser Edge Options – Provides exceptional cut quality, depending on the specific material and surface finish requirements.
• Adjustable Depth of Cut – Ranges from 5mm to 13mm, providing flexibility across different milling applications.

Why the Exacta-Set Face Mill Outperforms the Traditional Face Mill

Traditional face mills often lack adjustability and flexibility, leading to inconsistent finishes and limited tool life. The Exacta-Set solves these challenges by combining stability, adjustability, and durability into a modular, high-performance solution.

• Improved Surface Finish – The fully adjustable axial setting ensures a consistent, ultra-smooth finish, reducing secondary finishing operations.
• Extended Tool Life – The ability to fine-tune cutting parameters maximises PCD tool longevity, reducing overall tooling costs.
• Increased Process Security – The chip deflection system improves chip evacuation, preventing clogging and damage to delicate materials like CFRP and aluminium.

Case Uses: Real-World Performance of the Exacta-Set

Case Use: Aluminium Valve Body

• Tool Used: 8” Exacta-Set face mill
• Methodology:
  • Roughing in one pass in one direction
  • Finishing in one pass opposite direction
• Result: 400% increase in tool life

Case Use: Hardened Carbon Fibre Brake Rotor

• Tool Used: 6” Exacta-Set milling cutter
• Methodology:
  • 0.050” depth of cut in one pass
  • S2500 – F40”/min
• Result: 30% increased tool life

Choosing the Right Face Mill for Your Application

When selecting a face mill, it’s essential to consider material type, required surface finish, cutting speed, and tool longevity. PCD face mills like the Exacta-Set provide the best performance for non-ferrous materials, delivering high-speed cutting, exceptional surface quality, and extended tool life.

For those machining steel, titanium, or other ferrous materials, carbide face mills may be a better choice.

Want to learn more about how the Exacta-Set can transform your milling operations?

Contact Exactaform today for expert advice and tailored milling solutions.