Carbide end mill sharpening vs insert tooling vs throwing away and buying new

[Dustin beyer]

So I’m in a dilemma. I’m torn between making a cutter grinder which I’ve already got some parts and idea probably a bit over beefy but stuff I’ve got around and a good project. But I’ve been down this road soooo many times by the end of it I’m kicking myself going after all this time and money I could have bought a brand new universal cutter grinder or used lisle Deckel or something sweet vintage and precise. But with china ruling the market and how cheap I can just buy new end mills or insert tooling I’m at a conundrum! I think that’s the right word! But what’s your guys opinion do those Chinese universal u2 machines work I’d honestly prefer to find a delta Rockwell surface grinder or similar smaller machine but sooo hard to find and no matter how hard I squeeze I can’t seem to crap out money so yeah that too. Any thoughts guy?!

 

[markba633csi]

Well, if you are doing production then yea, buy or build a grinder. But most of us hobby types just buy new
I've been using the same handful of endmills for years

 

[7milesup]

Hello @Dustin beyer. Welcome to the best hobby machinist forum on the 'net.

Like you, I too wanted to build a tool and cutter grinder, not because it would make much economic sense but rather for pure enjoyment along with having a full understanding of how the machine works. I purchased the plans for the Acto Tool and Cutter Grinder from Machinery Plans listed below. But, I ended up buying a K.O. Lee tool and cutter grinder so building one is now on hold. It turns out that the K.O. Lee that I bought is quite worn, so who knows, I may end up using or selling the jig fixtures that came with it and either building the Acto one or buying something different.
I really want something like this for not only end mills, which I am not sure how often I will use it for that, but also to sharpen drill bits. Right now I have a lot of drill bits that need sharpening and yes, I could do them by hand, but I never get them 100% correct.

There is a member on here who built the Acto tool and cutter grinder... http://www.hobby-machinist.com/threads/home-made-tool-and-cutter-grinder.35679/

Also, Stephan Gotteswinter has modified a Deckel Chinese clone. Check out his channel, he does incredible work, and you might find a "few" other projects to put on your list. https://www.youtube.com/@StefanGotteswinter/videos

Sharpening End Mills 1

Design for, and method of making and using, an attachement for the Off Hand grinder for sharpening the end cutting edges of an end mill.

www.homews.co.uk

TINKFAB Pix

https://www.machineryplans.com/product/acto-tool-and-cutter-grinder/

 

[cathead]

If the edges are worn or broken on my carbide end mills, I regrind the tip edges by offhand grinding
on a diamond wheel so at least it will cut. You lose the 90 degree corner but the end mill is at least still usable.
Otherwise it is half way into it being a quandary or even possibly a predicament.

 

[pontiac428]

I like being able to sharpen end mills. That way, I always have a cutting tool to get the job done. I'd avoid the eBay U2 (or whatever), I bought a fixture for one to use in my Shars, and it was a totally different beast- narrow dovetails and unuseably sloppy in the head, where it mattered most. The Shars grinder has paid for itself. I got the early one like Robin Renzetti has. I can't get really small 4-flute grinds below 3/8" done, but small 2-flutes are no problem. I can get 1/2" end mills to the point of passably plunge cutting on a good day. Lathe bits come out perfect and sharp as razors. There is a learning curve, but once you know what a cutter needs, the possibilities open up. Some grinds require creative thinking, but if you're good with working out spatial relationships in your head, the light bulbs come on and you can accomplish a lot of what is needed in the shop. Plus you can make your own tools from scraps.

 

[C-Bag]

The Deckel style grinder is very different than the clones. Some of the clones approximate the Deckel, some are truly universal in that they use either the R8 collet or the 5c collets. The original Deckel style collets are small and expensive and it is called a d bit grinder which is different than an end mill. I love my U2 R8 grinder because like pontiac428 it is indispensable at resharpening end mills, making special cutting tools and resharpening drill bits. It takes up for less room than a surface style tool grinder and runs on 110v. I’ve not had to buy any end mills since getting it as I have been able to resharpen everything down to 1/4”. YMMV.

 

[jwmay]

Bought a deckel. Looked at it several times. Moved it out of my way several times over a few years time. Sold a deckel.
I like new end mills. I don’t think I want to sharpen them. Just not my thing.

 

[Huub Buis]

I grind my HSS end mills, drills and slitting saws on the small CNC lathe. I do not grind HSS-E, HSS-Co, HSS M35 and carbide tools because they all contain Cobalt and Cobalt dust is toxic.
When I grind, I have to cover the other machines because even if I use a vacuum cleaner, I still find grinding dust on the other machines. After grinding all machines are cleaned. That is time consuming, so I only grind once a year before the machines get their yearly maintenance.

I also do not grind my center drills (any more) because I can't get the center 100% on center due to the small runout of my 3 Jaw chuck or ER32 chuck.

 

[pontiac428]

I grind cobalt, tungsten steel, and carbide without fear, because grinding dust is coarse, far from the 10 micrometer thoracic or 4 micrometer respirable particle diameter cut points. It falls out immediately without aerosolizing, so it cannot be entrained into the lungs. Cobalt does not come off of tools when grinding like smoke from a cigarette (which is fine enough to be inhaled), it's broken off in chunks and settles in the area immediate to the grinding wheel. The settled dust is of little health concern also, unless you're going full Tony Montana on it. Just vacuum up afterwards, that's adequate hygiene for the substance.

 

[Dustin beyer]

The quorn work head also looks pretty decent but jwmay speaks truth also and yes even cheap Chinese but new are better then old resharpened ones unless you have a really good setup I’d imagine and I too hate grinding particles especially when it’s how do I say very abrasive material which is why I don’t use a tp grinder but on the other hand I love the concept and ingenuity and design of these t&c grinders but just don’t know if it’s practical for me. Someone would have to prove to me a quorn or lisle type tool can indeed produce a good enough end product to justify not just buying new?!? Does anyone use inset type endmills??