Tried a smaller diameter end mill for finishing and it cut my sanding time in half

I've been running 1/2 inch end mills for most of my work because that's what the last guy used. Last week I had a part with some tight internal corners so I switched to a 1/4 inch. Not only did the corners come out clean, but the surface finish was way better. I barely had to touch it with sandpaper. Now I'm wondering if I should be using smaller tools for roughing too. Has anyone else noticed a big difference stepping down tool sizes?

3 comments

3 Comments

oscarb715d ago

1/4 inch is way smaller than I ever bother going for finishing work. Honestly, I'm a little shocked you got a better finish going down that much, I always figured bigger tools leave a smoother surface. Might have to try it myself on my next job, see if I get the same results.

terrywilson4d ago

Tried this exact thing on some oak cabinets last month. Used a 1/4 inch roundover bit and took it real slow, like barely any pressure. Came out way cleaner than my usual 1/2 inch. The smaller bit just doesn't tear out the grain as bad on harder woods. Made a believer out of me.

smith.ray4d ago

Yeah "bigger tools leave a smoother surface" is a common myth for sure.