All types of milling cutters and accessories for hand routers

The cutter is a tool used for cutting, typically used with a manual milling machine or a stationary unit, to perform surface treatments on various materials such as wood, plastic, and metal. Since the cutter is designed for rotational motion, it usually takes on a disk-shaped or cylindrical shape, although the cutting edges can have complex shapes. There are different types of cutters available for hand routers, with wood processing being the most common. Even within wood cutters, there are further classifications. In this article, we will explore the various types of wood cutters and provide tips on selecting the right one for your needs.

Slot milling cutters

If you require selecting a groove with varying depths and widths, opt for a slot mill as your go-to tool. Its unique design enables this operation to be effortlessly performed on both the face and edge of the workpiece. The slot mill is primarily utilized for joining parts on the stud, and in conjunction with wood router attachments, it enables the cutting of seamless grooves of any desired width along a ruler.

Shaped

The tool allows you to shape the grooves in a way similar to braces. It not only selects the grooves inside the workpiece, but also alters the shape of the edges. When creating a complex pattern on the workpiece’s plate, start by using a straight cutter (groove cutter) to simplify the alignment of the shaped tooling. The images below showcase the main types of groove cutters.

Structural

After utilizing this tooling to machine the workpiece, a unique groove akin to a trapezoid (dovetail) or an inverted "T" is generated.

The utilization of this technique for joining components is regarded as highly trustworthy, as the studs are firmly inserted into the grooves of an identical configuration, rendering them inseparable by any alternative means.

Galvanized V-shaped

Despite the fact that the term "tile" typically describes a curved indentation or groove, V-cutters are also included in this classification. This particular tool enables you to create not only vertical grooves, but also grooves at specific angles. Additionally, chamfer cutters are frequently utilized for ornamental carving and altering the shape of edges in furniture manufacturing.

Pebble cutters

The cutting part of these tools is round. When you inspect the groove they make, it will have the shape of the letter "U". These cutters are utilized for enhancing the edges and endings of wooden items, forming intricate designs on the surface of the material or producing various grooves on the product.

This tool is the most basic one and it has a cylindrical shape. The groove created in the material has a rectangular shape.

This tool is commonly utilized with plunge routers.

Finger cutters with straight grooves are employed when a clean-bottomed rectangular groove needs to be chosen, such as for cutting door locks and hinges.

Edge milling cutters

Thrust bearings are commonly found in edge milling cutters, allowing for precise guidance of the tool along a template while machining the edges and ridges of workpieces.

The device produces half-circular projections on the perimeters of the workpieces. When paired with a lobe or groove cutter, the half-rod milling tool enables the creation of hinge joints. Furthermore, this tool is utilized in shaping rods with a circular cross-section, with the workpiece being processed from both directions.

These tools, also known as multi-profile cutters, have different profiles that can be used for various tasks. Craftsmen have the option to use just a portion of the tool or the entire profile depending on their needs. For the latter case, a machine with a minimum power of 1600 watts is required. Here are images of some multi-profile cutters:

Pebble cutters

Designed to create internal radii on workpiece ribs or to cut grooves with a circular cross-section. Galvanized milling tools are equipped with one or two bearings to ensure accurate alignment.

Cone milling cutters

• You can chamfer the workpiece’s edge.
• A way to embellish the worktop’s edge is by decorating it.
• Prior to gluing the workpieces together, an angular cut can be created on their edges, resulting in polygonal shaped products.

Another item that falls into this category is the edge cutter, with blades tilted at a 45-degree angle.

Folding

Rebate cutters are employed to create quarterings and grooves with a rectangular shape. The presence of a thrust bearing allows these cutters to be utilized on both flat and curved materials.

Various sizes of thrust bearings are utilized to modify the depth of the groove.

The groove disk cutter is also part of the same category. Its purpose is to create a groove in the workpiece in order to accommodate a T-shaped PVC edge.

Carving

Cutters are versatile tools that can be used to shape and style edges on workpieces. Whether you need an arched, straight, or custom-shaped edge, cutters can get the job done. They offer a wide range of possibilities and can be used in various ways:

• You can round the edge of a part to give it a smooth and polished finish.
• Create a rebated edge to add depth and definition to your workpiece.
• Add a half rod shoulder for a unique and eye-catching design.
• Give your workpiece a sponge edge for a soft and textured look.
• Create decorative edge treatments, such as those used for window frames.

In addition, lath cutters open up even more possibilities by allowing you to create intricate ornaments on the ribs and ends of wooden parts.

This set can also serve as a dual cutter, as depicted in the accompanying diagram.

By utilizing the dual cutter, it is possible to modify the gap between the components to accommodate the width of the material being worked on. Due to the presence of two components, the material is severed in a solitary motion, simultaneously on each face.

The straight edge mill, also known as an overrun or end mill, is employed to complete the ends of the workpiece or to achieve a precise 90-degree angle between the workpiece plate and its edge. The bearing can be positioned either at the top or bottom of the tool.

If the bearing is situated at the bottom, the template is secured beneath the workpiece. However, if the bearing is positioned at the top, the template is secured above the workpiece.

Aside from the facing function, the top bearing tooling also has the capability to function as a slotting tool. This allows it to cut a rectangular groove in the workpiece plate, using a template of a specific height. Normally, the diameter of the bearing matches the diameter of the tool, so it is level with the cutting edge. However, in certain situations, the diameter may be adjusted to a smaller or larger size, in order to broaden the tooling’s range of applications.

The corn cutter, also known as an edge cutter, is primarily designed for grinding and straightening the edges of a workpiece based on a template. The tool features a unique spiral arrangement of blades that allows for effortless chip removal and seamless operation.

Combination milling cutters

When it comes to combining workpieces, using combined tools is seen as the most efficient approach. These particular types of milling cutters incorporate both stud and groove elements simultaneously. This unique design allows for both profiles to be created in a single pass. Consequently, the bonding area of the edge expands, leading to an increase in the strength of the joint, which is highly beneficial.

Milling cutters for frames are tools that consist of multiple parts. The base serves as the foundation for all the cutting elements, which can be arranged in any desired order by the craftsman. A set of frame milling cutters typically includes the following components:

• base;
• cutting elements;
• bearing;
• washer;
• retaining nut.

It is not required to detach the shank from the machine’s collet when altering the configuration of the cutting elements. Simply loosening the fastener situated at the bottom of the tooling will allow for the removal of all its components. Thanks to the modular design of the tooling, the tool reach remains constant and does not require any readjustment.

In this set, you will find two milling cutters designed for different purposes: one for grooving and one for studding.

Tongue and groove milling cutters are designed with cutting elements that have a perfectly symmetrical profile, ensuring precise alignment when joining the machined parts.

However, one drawback of this particular tool is that the grooves and spikes are created using separate milling cutters. This means that the cutters need to be switched out and their positioning in relation to the machine sole may need adjustment.

For the production of veneer

Tools used for producing wagons follow a similar operational principle as the groove-and-spike tool, with one key distinction – when joining the parts, a V-shaped groove is created to mimic a bar. Additionally, a pair of two pieces is needed to create the joint.

Universal

By utilizing the tool, two planes can be produced that are completely compatible with one another, featuring a groove and a spike. Both of these components are positioned at an angle relative to each other.

A micro stud cutter is utilized for the purpose of joining components together.

One can utilize the tooling for both longitudinally splicing (when creating boards) and for end splicing of components.

Additionally, when it comes to splicing wood at an angle, one can employ a tooling from the combined tools series that enables the preparation of joints at a 45-degree angle.

It is worth mentioning that the identical combination cutter is employed for machining the workpieces intended for splicing. The initial design of the tooling enables the maximization of the jointing quality of components and also saves a significant amount of time since there is no necessity to alter the tool.

Figuire cutters

The tool is utilized in the production of fillets, particularly for the ornamental processing of the edges of the parts. The entire tooling features a thrust bearing that is securely fixed at the bottom. The cutter, equipped with a bearing, is capable of processing not only rectangular workpieces, but also ones with unique shapes. It is important to note that fillet tools come in a diameter range of 50 to 70m, so in order to achieve efficient usage, it is necessary to have a machine with a minimum power rating of 1500 watts. Attempting to carry out fillet processing with this type of tooling using a domestic cutter would prove to be an insurmountable task.

To fabricate doors using a hand router (specifically for kitchen facades), the acquisition of a specialized kit consisting of three components is required.

The assortment includes the following facade cutters: one fillet cutter and two furniture strapping jigs (profile-counterprofile).

Horizontal

Utilized to pre-finish the fillet, the edge will require further machining to form a spike for insertion into the frame slot.

Vertical

The production of skirting boards typically involves the utilization of vertical filigree cutters.

Horizontal double-sided

By utilizing this kind of equipment, the manufacturing procedure is greatly simplified, as it allows for the creation of both a connecting spike and a section of the fillet in a single tooling pass, with the fillet being designed to meet specific requirements.

In addition to the aforementioned types of tooling, numerous craftsmen also utilize homemade milling cutters. Typically, these are regular locksmith drills that have been resharpened in a unique manner. You can find out how to do this at home by watching the instructional video.

Criteria for choosing a wood cutting tool

When selecting wood cutters for a portable device, it is important to consider the following aspects of the tool:

Diameter and size of the shank

Please note that there are instances wherein foreign manufacturers of milling cutters might indicate the shank diameter in inches. Generally, if your machine is equipped with a collet clamp, you shouldn’t encounter any issues when it comes to installing the tooling, as long as the collet diameter matches the shank diameter.

It’s important to understand that the collet of a manual machine is not the same as a cam chuck on a drill, which allows for clamping tools of varying diameters. The inner diameter of the collet must strictly correspond to the shank diameter of the tooling. Challenges may arise if you purchase a tool with a 1/2ʺ (12.7 mm) shank and attempt to insert it into a collet with a 12 mm diameter. On the other hand, a 6 mm shank will fit into a 1.4ʺ (6.35 mm) collet without any problem.

Before purchasing a cutter, particularly a costly one, it is advisable to carefully read the machine’s manual and identify the type of collet that is installed on the machine.

The length of the tooling’s shank is also of importance. Not all tooling comes with extended shanks, and at times their size may be insufficient for certain applications, such as when expanding deep grooves. Additionally, long shanks may be necessary when the machine is securely fastened under a table. In such cases, it is customary to utilize a cutter extension, which is clamped into the machine’s collet.

Blade material

When choosing the tooling, it is crucial to consider this essential factor. The tooling can be manufactured using high-speed steel (HSS) or carbide steel (HM). HSS blades are highly effective in handling soft wood with low density. However, they may not be suitable for processing hard wood. In such situations, carbide-tipped blades can be utilized as a replacement option.

Location of cutting elements

The blades of the tool can be positioned either vertically, parallel to the shank’s axis, or at an inclined angle. Blades that are positioned vertically function as a planer and are more effective at chopping wood rather than cutting it. Consequently, if these blades become slightly dull, they will leave marks on the surface that will need to be sanded down.

On the other hand, blades that are inclined to the tool’s axis work with greater precision and do not create wood chips.

Stone cutters

You can use conventional wood routers with carbide blades to work with artificial stone using a handheld router. However, it is important to note that artificial stone is a composite material that contains tiny abrasive particles. This means that even if the cutter is made of carbide material, it will only be able to process up to 10 linear meters of the stone workpiece before the blades become dull and unable to provide the necessary cleanliness for achieving high-quality connections, such as glued surfaces.

Therefore, experts recommend utilizing the top-quality cutters produced by renowned manufacturers such as Festool, Leuco, Titman, Leitz, and Dimar. The lifespan of cutting tools produced by these companies is 5-10 times longer compared to regular carbide tools. These "branded" cutters are suitable for working with composite materials and can be used to process 60 to 100 meters of composite.

Cutters used for working with wood and stone may look similar and even have the same names. Some of them are commonly used for cutting stone. However, there are cutters specifically engineered for machining composite products.

This stone cutter is designed for shaping the edges of kitchen and bathroom sinks, as well as composite countertops. Typically, it takes two passes of the tool to create a complete bevel.

Additionally, there exists a variant of the "anti-overflow" cutter that incorporates a thrust bearing.

Wave" cutter

This tool is specifically designed for surface preparation prior to splicing. The cutting part of the tool features a distinctive wave-shaped profile.

Groove for inlay

The tool is employed to choose the channel that will later be filled with composite materials.

Stone repair kit

The purpose of this kit is to fix any imperfections on artificial stone items. There are two components included in the kit. One is designed to create a filling, while the other creates a corresponding opening for it.

CERATIZIT cutters are also suitable for processing composites.

These diamond cutters are known for their durability due to their high wear resistance. They are manufactured using a process known as sintering, in which multiple layers of diamond chips are fused together. The use of a multilayer coating significantly extends the tool’s lifespan, as fresh layers of abrasive material continually replace the worn layers during operation.

There is no specific metal tooling specifically designed for handheld cutters. Typically, craftsmen utilize tooling that is designed for machine tools, with an appropriate shank diameter. End mills are commonly used on handheld units to create grooves. However, it is important to note that milling machines operate at high speeds, which is not ideal for end cutters. As a result, it is recommended to remove the metal in thin layers, around a few tenths of a millimeter thick, over multiple passes. The accompanying image showcases a spiral metal cutter.

The routers also have the capability to be equipped with different types of burrs that are suitable for cutting various materials including steel, cast iron, stainless steel, brass, and even titanium. However, it is important to note that these routers typically have a smaller shank diameter (6 mm) and may require an adapter to fit into an eight-millimeter collet.

There are different types of metal burrs available, including:

1. Disk: These burrs are versatile and can perform a variety of cuts and grooves.
2. Conical (60°): These burrs are specifically designed for countersinking holes.
3. Rounded taper. Ideal for machining interfaces, removing welded seams, and shaping surfaces.
4. Pointed taper. This versatile tool is perfect for machining sharp corners, aligning mating points of parts, and milling in hard-to-reach areas.
5. Oval-shaped. Used for machining, enlarging holes, and aligning welds in the corners of parts.
6. Flame-shaped. With its universal design, this tool is great for creating and shaping moldings.
7. The pointed tool is in a spherocylindrical shape and can be machined between planes joined at an acute angle.
8. The rounded tool is in a spherocylindrical shape and can be used to machine joints with internal radii.
9. The spherocylindrical tool is suitable for processing edges, profiles, weld seams, and radius grooves. Additionally, it can be used to remove chamfers and burrs and prepare surfaces for welding.
10. The tool with a smooth face is cylindrically shaped and is used for machining contours, seams after welding, edges, chamfering, and deburring.
11. Cylindrical tool with teeth is commonly used for the same purposes as the tool with a smooth end. However, what makes this type of tool unique is its ability to work simultaneously in two planes at right angles.



Attachments for the hand router



One of the primary functions of the different adaptations for this unit is to enhance the device’s functional capabilities. While some attachments are included with the milling machine, others have to be bought separately or created manually.

This feature is included on every router as a default.



A stop is used to perform straight cuts on workpieces, with the edge of the workpiece or the guide rail serving as a reference guide.

Guide rail

The guide rail serves as a support for the machine stop, facilitating the straight-line milling process for workpieces.



Dagger

The radial milling and cutting circles can be performed with the help of this device that is connected to the soleplate of the machine.




Grooving

Shown in the illustration below is a router attachment that is utilized for cutting grooves with a designated width.



The width of the slot is controlled by a single pad. In this particular situation, a straight slot cutter is utilized, which has a top bearing.

Copier

In order to transfer intricate designs or patterns onto a workpiece, specialized tools called copiers (also known as pantographs) are employed.



The copier operates in the following way:

• The piece being worked on is positioned below the pantograph unit.
• The design or pattern that needs to be replicated is placed at the desired distance from the copier.
• The pantograph pointer is set to its initial position, and then the machine motor is turned on.
• All the movements of the pointer along the pattern are precisely transferred to the milling machine, which then cuts a duplicate of the desired pattern onto the workpiece.

The primary function of the copy ring is to shield the template from the cutting blades. Furthermore, as the copy ring glides along the template’s edge, it effortlessly imprints all of its contours onto the cutter, enabling the machining of the component underneath the holding device.



If the size of the hole in the template exceeds the dimensions of the fixture’s footprint, it is possible to install it on a suitable pad of appropriate size.



Machining bodies of rotation

This basic device enables you to create both crosswise and lengthwise indentations in cylindrical workpieces (such as turned table legs, posts, and balusters).



Spike cutter

To create studs for drawer joints, whether they are straight or dovetail studs, an attachment for cutting studs is employed.

Utilizing this attachment enables the production of spikes with uniform spacing, ensuring flawless joining of the components.

The tongue and groove fixture

One of the most frequently used joints in carpentry is the tongue and groove joint.



Special devices called pantorouters are used to create this joint.




Although the design may seem complicated, this machine can be easily built by hand based on the available internet drawings.

Table for milling machine

By setting up the portable unit on a table, you can transform it into a fixed mini-machine. This is a practical solution for milling small and elongated workpieces that cannot be secured with traditional clamps. There are ready-made milling tables available, specifically designed for securing hand-held milling machines. You can find one below, manufactured by the renowned Corvette company.



However, it has been observed in practical situations that the majority of craftsmen opt for crafting their own milling tables, as the design itself is not particularly complex. The milling machine table can be fabricated using either thick plywood or LDFP with a thickness of 16 mm.



Fixture for fillets

If you were to take a piece of plywood and cut it into the shape of an isosceles triangle, you could then attach it to the soleplate of a cutter. This would create a straightforward tool for working on door trims, much like the one depicted in the accompanying illustration.



This accessory allows for further decoration of pre-finished doors without the need for disassembly or the use of templates.

How to sharpen a router at home



It is important to ensure that the cutter is completely clean, with no carbon deposits or contaminants, before proceeding with the sharpening process. To achieve this, it is recommended to use a designated cleaning liquid, as illustrated in the accompanying figure.



To remove the carbon buildup, apply the product to the cutting surfaces of the tooling and allow it to dissolve the soot for a few minutes. Then, take a regular toothbrush and carefully brush away the remaining dirt from the blades. Once the cleaning is complete, you can proceed with the sharpening process. To do this at home, you’ll need to get a set of diamond sharpening stones with different grain sizes.



Coarse sharpening bars with a larger grain are utilized for the purpose of sharpening. However, it is essential to always complete the blade dressing process by polishing it with the finest abrasive.

To sharpen a router, follow the steps outlined below:

• Position the bar on the table edge and apply water to moisten it. Secure the tooling if needed;
• Place the tooling on the bar, ensuring that its cutting edge is in full contact with the bar along its entire length;
• Delicately move the cutter over the emery board using smooth motions and maintain consistent pressure. Regularly wet the cutter with water;
• Perform the same number of movements for each blade of the tooling, ensuring that the edges are ground evenly.

If the tooling being prepared for sharpening features a thrust bearing, it must be removed before commencing the process.