Difference Between a Mill File and a Flat File

The design of the flat files is mostly tapered at width and thickness towards the endpoint of the file. It is a great tool with teeth on both sides. Generally used to sharpen the blades and knives. In contrast, the mill files are featured with one safe edge. The cut pattern of the mill files is always a single-cut type. Used for primary or initial or primary finishing and draw filing. 

Metal Hand Files

The metal files are designed to fulfill various tasks for cutting, shaping, surface finishing, and deburring on any metal and wooden workpiece. The use of metal hand files depends on the requirement of the level of finish and shape of the workpiece. Industrial metal hand files can be distinguished according to their sizes, shapes, purposes, and materials. Mostly, the hand files are made of high-carbon steel and alloys. The cut pattern shows the coarseness of the metal files. 

Here are the key differences between Mill files and Flat files.

What is a Mill File?

When a small quantity of material needs to be cut from a workpiece, a mill file is a necessary tool for both metalworking and woodworking applications.

It is one of the most common types of filing tools used in shaping and cutting projects. The purpose of the mill files is similar to a milling machine, mainly to get a good initial surface finish on the small parts. The mill file is constructed with a single-cut pattern on both faces. The single-cut pattern is a diagonal pattern of teeth to achieve the removal of material. It helps to cut and shape the workpiece efficiently and quickly. The side edges of the files are tapered for detailed work.

Applications of Mill Files

Mill files are typically used for deburring a workpiece. There are different sizes and shapes of the mill files available to choose from and complete the tasks with efficiency. 

In most industries, it is used to fulfill small finishing jobs. Ideal file to use for initial shaping and surface deburring in DIY projects.

The mill files are constructed with a variety of sizes for many useful applications. For some metalworking jobs a small size of metal mill files is better.

If you need to work on any precise finishing tasks, small or narrow mill files are great for it. Larger mill files have a wider tooth design, which is excellent for larger finishing jobs. These tasks include metal plate surfacing, working on corners of a wooden block, etc. 

Pros Of Mill Files

The following are some benefits of using mill files:

• Versatile: In addition to being commonly used for tool sharpening, mill files can be used for common metalworking chores like burr removal, intricate area shaping, and fine detailing, making them perfect for a variety of applications.

• Accuracy: Because of their tapered design and single-cut teeth shape, mill files provide more accurate finishes than flat files. A workpiece is finished precisely and finely as a result.

• Robust: Compared to flat files, premium mill files have a longer shelf life. The lifespan of files will be extended with appropriate maintenance and attention.

Cons Of Mill Files

The following are some drawbacks of using mill files:

• Restricted versatility: despite their versatility, mill files are only used for a few specific tasks, such as sharpening tools and working with fine metal.

• Slow material removal: Mill files feature single-cut teeth, which means they remove material very slowly, in contrast to flat files, which have double-cut teeth. As a result, mill files require more time and effort to remove a given quantity of material.

• Need professionalism: It takes skill and experience to cut using mill files effectively. Accurate cutting requires more than just expertise. It is easier for novices to cut and shape accurately with control and knowledge. 

What is a Flat File?

The Flat File has edges that are tapered towards the points from one point near the middle part of the edges. These handheld files are double-cut (Bastard cut) patterns for fast cutting and finishing actions on the workpiece. Both the faces of the file have cutting teeth with diagonal double-cut patterns. Edges of the file have a single cut.

The crisscross pattern of the teeth ensures the operation of the file at opposite angles. Also, provides aggressive material removal and better-finishing results in less time. These hand flat files with bastard cut design are tapered at the tip which helps in detail work. 

Applications of Flat Files

They are also called general-purpose files and are used for filing metal surfaces, wooden frames, blocks, and other internal and external metal surfaces. 

The manufacturing sector uses these double-cut hand files for a variety of metalworking tasks.

The aggressive action of the metal hand flat file is useful in rapid stock removal. They are used by machinists, repairmen, carpenters, etc. It is easy to use in most DIY projects.

Some of the industrial applications include foundry casting, wood framing, repairing, descaling, die casting, and forging works. The hand-flat file is suitable for use on iron bars, stainless steel, ferrous metals, mild steel, plastics, hard rubber, and wood.

Pros Of Flat Files

The following are some benefits of flat files:

• Ideal for material removal: Flat files are perfect for material removal because of their double-cut teeth design, which saves time and effort. Their efficiency and effectiveness are evident even when they are cutting large chunks of wood and metal.

• Versatile: Flat files can be used for many different jobs, such as carpentry, metallurgy, woodworking, smoothing, and shaping. Flat files are easily able to handle both small-scale projects and large-scale industrial applications.

• Easy to use: Unlike mill files, flat files are simple to use and don't require any special knowledge or abilities. Therefore, it is perfect for both professionals and do-it-yourselfers.

Cons Of Flat Files

The following are some drawbacks of flat files:

• Rapid wear: The strong cutting action of double-cut teeth in flat files allows for rapid wear. Although these are made to remove material more quickly and effectively, too much pressure or force will also cause a file to wear down more quickly.

• Less accurate: Because of its flat design and aggressive cutting style, flat files are less precise than mill files. In contrast to mill files, its aggressive cutting style will not produce a fine and smooth finish.

• Not appropriate for fine and complex detailing: Flat files are not appropriate for fine and complex detailing. Flat files cannot contain forms or navigate complex spaces because of their flat architecture. Therefore, it is not suitable for fine-detailed tasks.

Conclusion

We hope you have understood the difference between the mill and flat files. It is recommended to wear your safety gear (according to the tools used) whenever working with these industrial tools. These metalworking tools will surely help in your next projects.