Rigidity & Mechanics // Beam Deflection

Tool Deflection &
Chatter Calculator

Model end mill bending deflection (δ = F·L³ / 3EI) under lateral cutting forces. Prevent surface chatter, tapered wall drift, and catastrophic cutter fracture.

Tool Geometry & Stickout

Tool Substrate (Modulus of Elasticity)

Extreme stiffness (~3x higher than steel). Low deflection, but brittle under high shock impacts.

Shank / Cutter Diameter (D)6.0 mm

1.0 mm (Micro)6.0 mm (Standard 1/4")25.0 mm (1")

Stickout Length from Collet (L)24.0 mm

5 mm (Stubby)24 mm (4x D)100 mm (Deep reach)

Radial Cutting Force (Fc)85 N

≈ 19.1 lbf (Pounds-force)

Flute Core Ratio (d_core / D)80%

Core: 4.80 mm

Estimated Cutting Force Load Presets

Cutter Mechanics Analysis

Tip Deflection (δ)

Radial Tip Deflection

25.1µm (Microns)

= 0.0251 mm (0.986 thou / mils)

Stickout Ratio (L/D):4.0x (Rigid)

Max Stickout for <25µm:24.0 mm

Area Moment of Inertia (I):26.06 mm⁴

Severe Deflection (> 0.025 mm / 0.001"). High probability of regenerative chatter, taper error, and cutter snapping. Push endmill deeper into collet or decrease radial DOC.