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Aggressive Milling Charts:

Aggressive Recommendations for Milling with Millstar Ball Nose Tools (Inch)

  1. Prerequisites: Maximum tool extension length to insert diameter L / D = 4 / 1.Use a of a rigid machine, part and set-up.
  2. For finishing with small pick feed / step-over (P), reduce the feed rate so feed per tooth equals pick feed ( fz = P)
  3. On longer tool extension, max. L / D = 7 / 1: reduce feed and speed to 60%
  4. Use of coolant: for all stainless steel (SS) use through the spindle or flood coolant. For gray cast iron use air or coolant. We recommend a liquid coolant concentration of 9 - 10%, not the usual 3 - 4%. This will lubricate and not only cool the cutting edge for longer tool life and better finish. For all other die/mold materials use air-mist / minimum quantity lubrication (MQL) or high pressure air blow. Vegetable based oil mist works best in MQL / mist use.
  5. When using a spindle taper CAT-40 / HSK 63 or equivalent instead of CAT-50 / HSK 100, use max. tool diameter D = 3/4".

The recommendations are for ball nose cutting with Millstar inserts and coatings as shown in the table and schematic of tool shown below. When tip cutting only on flat surfaces, feed rate may be increased by up to 30%. For other materials or for specific application cases, contact the factory with as much detail as possible.

Material Hard-ness Cut Depth Cut Width Recom-mended Coating
Type 		Cut Speed at Ø D Max. Feed per Tooth fz
for insert Ø D

HRc ap max. ae max. insert recom-mended SFM .250- .375 .500- .625 .750- 1.00 1.250
H13 < 41 0.10 D 0.45 D RB-N TLN-Ex./TCN 600-1200 .008 .010 .012 .014
H13 41-54 0.06 D 0.40 D RB-N TLN-Exalon 600-1200 .008 .010 .012 .012
H13 55 + 0.05 D 0.35 D RB-N TLN-Exalon 450-600 .006 .010 .010 .010
A2 < 41 0.10 D 0.40 D RB-R TLN-Exalon 600-1200 .008 .010 .012 .014
A2 41-54 0.06 D 0.40.D RB-N TLN-Exalon 600-800 .008 .010 .012 .012
A2 55 + 0.05 D 0.35 D RB-N TLN-Exalon 450-800 .006 .010 .010 .010
P 20 < 41 0.10 D 0.45 D RB-N TLN-Ex./TCN 600-1200 .008 .010 .012 .014
P 20 41-54 0.06 D 0.40 D RB-N TLN-Exalon 450-800 .008 .010 .012 .012
NAK 55 < 41 0.10 D 0.45 D RB-N TLN-Exalon 600-1200 .008 .010 .012 .014
NAK 80 < 41 0.10 D 0.40 D RB-N TLN-Exalon 600-1200 .008 .010 .012 .012
D 2 < 41 0.10 D 0.45 D RB-R TLN-Ex/TCN 450-800 .008 .010 .012 .012
D 2 41-54 0.06 D 0.40 D RB-N TLN-Exalon 450-800 .006 .008 .010 .010
D 2 55 + 0.05 D 0.35 D RB-N TLN-Exalon 345-460 .006 .008 .010 .010
CPM 9V & 10V < 41 0.10 D 0.40 D RB-R TLN-Ex/TCN 600-1200 .008 .010 .012 .012
CPM 9V & 10V 41 + 0.06 D 0.35 D RB-N TLN-Ex/TCN 350 - 800 .006 .008 .010 .010
Titan. 6Al4V - 0.10 D 0.45 D RB-R TLN-Exalon 600-1200 .008 .010 .012 .012
4130-4150 < 41 0.10 D 0.45 D RB-R TLN-Ex/TCN 600-1200 .008 .010 .012 .012
Finkl FX1 & 2 - 0.12 D 0.45 D RB-R TLN-Ex/TCN 800-1500 .008 .010 .012 .012
PX5 - 0.12 D 0.45 D RB-R TLN-Ex/TCN 1200-1500 .008 .010 .018 .020
Gray Cast Iron < 41 0.02 D 0.75 D RB-N/ R TCN/ TLN 800-3000 .008 .010 .014 .015
400 series SS < 41 0.10 D 0.45 D RB-R TLN-Ex/TCN 600-3000 .008 .010 .014 .016
400 series SS 41-54 0.08 D 0.40 D RB-N TLN-Exalon 600-1200 .008 .010 .014 .016
300 series SS < 41 0.10 D 0.45 D RB-R TLN-Ex/TCN 345-800 .007 .010 .012 .012
S7 < 41 0.10 D 0.45 D RB-N TLN-Ex./TCN 600-1200 .008 .010 .012 .014
S7 41-54 0.06 D 0.40 D RB-N TLN-Exalon 600-1200 .008 .010 .012 .012
S7 55 + 0.05 D 0.35 D RB-N TLN-Exalon 450-600 .006 .010 .010 .010
Aluminum - 0.50 D 1.00 D RB-NF TCN/ZrN 1000-3000+ .008 .010 .025 .028

2 or 3-dimensional milling with the following insert engagement:

tip-cutting   up-slope cutting   down-slope cutting   side-cutting
     

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Aggressive Recommendations for Milling with Millstar Ball Nose Tools (Metric)

  1. Prerequisites: Maximum tool extension length to insert diameter L / D = 3 / 1. Use a of a rigid machine, part and set-up.
  2. For finishing with small step-over (P), reduce feed to equal feed per tooth fz = P
  3. On longer tool extension, max. L / D = 7 / 1: reduce feed and speed to 60
  4. Use of coolant: for all stainless steel (SS) use through the spindle or flood coolant. For gray cast iron use air or coolant. For all other die/mold materials use air-mist (MQL) or air blow, air only over 40 HRc. We recommend a liquid coolant concentration of 9 - 10%, not the usual 3 - 4%. This will lubricate and not only cool the cutting edge for longer tool life and better finish. Vegetable based oil
    mist works best in MQL / mist use.
  5. When using machines with a spindle taper SK #40 or equivalent, use maximum tool diameter D= 20 mm (R 10).

The recommendations are for aggressive cutting with Millstar ball nose inserts and coatings as shown in the table and schematic of tool shown below. When tip cutting only on flat surfaces, feed rate may be increased by up to 30%. For other materials or for specific application cases, contact the factory with as much detail as possible. More materials are in our data bank, please inquire.

Work material Specifications

Material hardness

Cutting depth

Cutting width

Recom-
mended

Coating type recommended

Cut speed at Ø D

Max. feed per tooth fz at cutting insert Ø D (mm)
USA / W.-Nr. / JIS HRc Ap max. Ae max. insert
m / minute 6-8 10-12 16-20 25-32
H13 / 1.2344 /SKD61 < 41 0.10 D 0.45 D RB-N TLN-Ex./TCN 244 - 365 0.1 0.2 0.3 0.3
H13 / 1.2344 /SKD61 41-54 0.06 D 0.40 D RB-N TLN-Exalon 244 - 365 0.1 0.2 0.25 0.25
H13 / 1.2344 /SKD61 55 + 0.05 D 0.35 D RB-N TLN-Exalon 185 0.1 0.2 0.2 0.2
A2 / 1.2363 /SKD12 < 41 0.10 D 0.40 D RB-R TLN-Exalon 244 - 365 0.1 0.2 0.3 0.3
A2 / 1.2363 /SKD12 41-54 0.06 D 0.40.D RB-N TLN-Exalon 183 - 244 0.1 0.2 0.25 0.25
A2 / 1.2363 /SKD12 55 + 0.05 D 0.35 D RB-N TLN-Exalon 183 - 244 0.1 0.2 0.2 0.2
P 20 / 1.2330 < 41 0.10 D 0.45 D RB-N TLN-Ex./TCN 244 - 365 0.1 0.2 0.25 0.25
P 20 / 1.2330 41-54 0.06 D 0.40 D RB-N TLN-Exalon 183 - 244 0.1 0.2 0.25 0.25
D 2 / 1.2379 / SKD11 < 41 0.10 D 0.45 D RB-R TLN-Ex/TCN 183 - 244 0.1 0.2 0.3 0.3
D 2 / 1.2379 / SKD11 41-54 0.06 D 0.40 D RB-N TLN-Exalon 183 - 244 0.1 0.2 0.25 0.25
D 2 / 1.2379 / SKD11 55 + 0.05 D 0.35 D RB-N TLN-Exalon 105 - 140 0.1 0.2 0.2 0.2
Gray Cast Iron / GG < 41 0.2 D 0.75 D RB-N/R TCN or TLN 350 - 900 0.15 0.25 0.3 0.35
Cast Iron / GGG 41+ 0.06D 0.40 D RB-N TLN-Exalon 250-400 0.1 0.2 0.3 0.3
Aluminum
0.5 D 1.0 D RB-NF TCN or ZrN 300-1000 0.2 0.25 0.6 0.7
Titanium (6Al 4V)
0.10 D 0.45 D RB-R TLN-Ex/TCN 183-365 0.15 0.2 0.3 0.35

2 or 3-dimensional milling with the following insert engagement:

tip-cutting   up-slope cutting   down-slope cutting   side-cutting
     

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