Dual-Ended Use
When one cutting end becomes dull, the tool can be reversed in the holder to use the second profile.
Mills / Corner rounding tools
Double End Corner Rounding End Mills
What Are Double End Corner Rounding End Mills and How Do They Work?
Double end corner rounding end mills are form tools that apply uniform outer radii to sharp workpiece edges. Concave profiles are ground on both ends of a solid carbide or HSS body, allowing the second end to be used after the first wears.
Form Radius Shearing
The concave arc shears vertical and horizontal edges into a uniform 90° convex corner radius.
Single-Pass Profiling
The tool forms an edge radius in one 2D contouring pass instead of repeated 3D ball-nose stepover passes.
Edge Blending
Precision-ground flutes blend the radius into adjacent flat surfaces and reduce the need for hand deburring.
Key Features and Benefits of Double End Corner Rounding End Mills
Double-Ended Design
Provides two usable cutting profiles on one shank to improve tooling economy.
Single-Pass Profiling
Cuts the specified radius in one contouring pass and can reduce cycle time versus 3D surface sculpting.
Repeatable Form Geometry
Precision profile grinding supports consistent edge radii across production parts.
Reduced Tool Inventory
Two cutting ends can reduce the number of replacement tools held for edge-finishing work.
Rigid Construction
Solid-core geometry helps suppress chatter and supports smooth edge finishes.
Double End Corner Rounding End Mills Specifications
| Specification | Range / Details |
|---|---|
| Radius Sizes | 1/64 in to 1/4 in+; metric 0.5 mm to 6 mm+ available |
| Tool Format | Double-ended, with cutting profiles on both ends |
| Flute Count | 2 or 4 flutes |
| Profile Geometry | 90° concave form radius |
| Shank Type | Straight cylindrical |
| Tolerance | Sub-micron ground form-radius accuracy |
Materials and Coatings Available for Corner Rounding Tools
| Material / Coating | Best For | Key Advantage |
|---|---|---|
| Solid Carbide | Stainless steel, titanium, hardened steels, and cast iron. | High rigidity helps limit tool flex and maintain form-radius accuracy. |
| TiAlN / AlTiN Coating | Tough alloy steels, high-temperature metals, and dry milling. | Thermal stability helps protect cutting lips from friction and thermal wear. |
| DLC / ZrN Coating | Aluminum, copper, brass, and non-ferrous plastics. | Low friction helps reduce material welding and built-up edge on the flutes. |
Solid carbide supports rigid form cutting, TiAlN or AlTiN suits thermally demanding alloys, and DLC or ZrN helps manage adhesion in non-ferrous materials.
Which Machines Use Double End Corner Rounding End Mills?
CNC Machining Centers
3-, 4-, and 5-axis centers use these tools for automated perimeter radiusing and edge deburring.
Swiss-Type CNC Lathes
Live-tooling spindles use them to radius outer shoulders on small turned components.
Precision CNC Routers
They perform edge-rounding passes on aluminum sheet parts and engineering plastics.
Applications and Industries for Corner Rounding Tools
Top Edge Radiusing
Applies functional corner radii to external top shoulders and part perimeters.
Automated Edge Deburring
Uses programmed CNC passes to remove sharp edge flash in place of manual bench deburring.
Ergonomic Part Finishing
Rounds exposed edges on medical housings, consumer electronics, and automotive interiors.
Stress Relief Machining
Replaces sharp external corners with radii to reduce stress concentrations in structural parts.
Frequently Asked Questions About Double End Corner Rounding End Mills
What is the main advantage over a single end model?
A radius is ground on both ends, so the tool can be reversed after the first end wears instead of replacing the tool blank.
How are tool offsets set for a double-ended corner round tool?
Tool paths are typically programmed from the major diameter or theoretical radius center. After reversing the tool, measure the projection length with a tool setter and update the Z-height offset.
Are these tools suitable for internal-hole deburring?
They are primarily intended for external top edges, shoulders, and outer perimeters. Back corner rounding tools are better suited to internal-hole exits and backside edges.
Which flute count should I choose?
Two flutes provide larger chip valleys for aluminum and plastics. Four flutes add tooth density and rigidity for steels, stainless steel, and titanium.
Can Bauron produce custom double end corner rounding end mills?
Bauron can review non-standard radii, extended shanks, neck-clearance tapers, and application-specific coating requirements from manufacturing drawings.
Shared engineering resource
Design and Engineering Support
Bauron provides design and engineering support for custom geometries and coating selections. Share the workpiece material, radius, reach, tolerances, and machining conditions for technical review.
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