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Application Tips
END MILLING APPLICATION TIPS (See speci c tool series for any additional tips).
Tool • Whenever possible, select an end mill with the largest diameter, shortest flute length,
and shortest overall length for the best rigidity
Tool Holders
Workpiece • Long flute tools are not intended for pocketing, slotting, or heavy profiling – limit Rw to .02D
Machine • High Performance tools minimize cycle time and extend tool life
Coolant • Holders with adequate gripping pressure and TIR are required
• Stub holders or zero length collet style holders are recommended for heavy stock removal
Methods • When using solid holders, hand ground screw flats are not recommended
• Secure clamping of the workpiece will reduce chatter and deflection
• Spindle must be in optimum condition for precise TIR and maximum tool life
• Sufficient horsepower is required to perform at recommended speeds and feeds
• Reduce rates for low power machines to prevent workpiece and / or tool damage
• Avoid re-milling chips through use of air blast or liquid coolant as necessary
• Maintain clean coolant with appropriate concentration
• General recommendations:
–Water Soluble Oil or Air Blast: Tool Steels, Mold & Die Steels, Carbon or Alloy Steels
–Water Soluble Oil: Stainless Steels, Titanium, High Temperature Alloys, Non-Ferrous Alloys
• Climb milling is generally preferred
• Attention to programming details, tool holders, TIR, balance, fixturing, etc. improve cutting tool
performance and extend tool life
END MILLING GUIDELINE
D1 = cutting diameter L2 = flute length
Speeds and Feeds for Cut Types are based on Radial Width ( Rw ) and Axial Depth ( Ad )
Reductions to Speeds and Feeds may be necessary when: • Rw and Ad exceed recommendations
• Using long flute or extended reach tools
• Using long tool holders
• Machining materials harder than listed
ENTRY METHODS
Pre-Drilled Hole Helical Ramp Plunge
Pre-drilling is the preferred Alternative methods are helical and ramping. Plunge only in non-ferrous
entry method for most Use slotting speeds and 25% to 50% slotting and short-chipping materials
applications. feeds. Engage at about 5° for General Purpose using slotting speeds and
tools and 5° to 10° for High Performance tools. 25% slotting feeds.
END MILLS END MILLS 125
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