Weldon Flat End Mill Cutter?

[dulltool17]

I avoid the 'hang-up' of the setscrew by lining up the cutter shank outside the holder, gauging the insertion, then marking the shank with a sharpie. Works every time.

Actually, I suppose you could mill the flat twice as long and it wouldn't matter.

 

[kd4gij]

Surface grinder

 

[EmilioG]

You are all correct,..but, the Weldon flat a. Looks better and b. aids in the insertion of the tool.
Both are not "critical for application", but if I can do it, I will...the 45°'s of course. I can also cut the 45's later
if I have access to the tooling/grinder. Thanks to all for the replies.

 

[jbolt]

Yes. Using a square or corner chamfer end mill will work and leave straight 90° sides. It just doesn't look as good.
The problem with doing two 45's is that I need repeat ability. I need to move the tool for each side and insert cutter or a collet block
holder will be needed. If I had a cutter grinder, it would be cake. The collet cutter blocks leave too much over-hang but that can be solved
with a the right height V block or metal block to minimize flex. I just need a small flat so I'll probably settle with a straight flat. It's for a set screw.
Thanks for all of your replies and ideas.

Does it need to be held in a collet block? If you are not indexing it to another flat or feature I would hold it directly in a vise if you are concerned about rigidity.