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Aggressive Milling Charts:

Aggressive Recommendations for HSC Milling with Moldstar Ball Nose End Mills (Inch)

  1. Prerequisites: Maximum tool extension length to tool shank diameter L / D = 5 / 1. Use a rigid machine, part and set-up.
  2. For finishing with small step-over / pick feed (ae), use a feed per tooth (fz) equal to step-over: fz = ae (Small step-over is defined as ae = 2% of tool diameter D or less).
  3. On longer tool extension (max. L / shank 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 (9 -10% concentration). This will lubricate and not only cool the cutting edge for longer tool life, reduced chip welding and better the finish. Vegetable based oil mist works best in MQL / mist use. For gray cast iron use air or coolant. For all other die/mold materials use air-mist (MQL) or air blow, air blow only over 40 HRc.

The recommendations are for aggressive cutting with Moldstar ball nose tools and coatings as shown in table 1 and tool engagement shown below. When tip cutting only on flat surfaces, feed rate and spindle speed may be increased by up to 30%. For other materials or for specific application cases, contact the factory with as much detail as possible.

Work material Specifications

USA / W.-Nr. / JIS

Material Hardness

HRc

Cutting depth ap

maximum

Cutting width ae

maximum

 Recommended Coating type Recommended Cutting Speed Range at D
Vc(m/minute)
H13 / 1.2344 / SKD61 < 41 0.10 D 0.45 D TLN-Exalon 800 - 1200
H13 / 1.2344 / SKD61 41-54 0.06 D 0.40 D TLN-Exalon 800 - 1200
H13 / 1.2344 / SKD61 55 + 0.05 D 0.35 D TLN-Exalon 600
A2 / 1.2363 / SKD12 < 41 0.10 D 0.40 D TLN-Exalon 800 - 1200
A2 / 1.2363 / SKD12 41-54 0.06 D 0.40.D TLN-Exalon 600 - 800
A2 / 1.2363 / SKD12 55 + 0.05 D 0.35 D TLN-Exalon 600 - 800
P 20 / 1.2330 < 41 0.10 D 0.45 D TLN-Exalon 800 - 1200
P 20 / 1.2330 41-54 0.06 D 0.40 D TLN-Exalon 600 - 800
D 2 / DieVar/1.2379 / SKD11 < 41 0.10 D 0.45 D TLN-Exalon 600 - 800
D 2 / DieVar/1.2379 / SKD11 41-54 0.06 D 0.40 D TLN-Exalon 600 - 800
D 2 / DieVar/1.2379 / SKD11 55 + 0.05 D 0.35 D TLN-Exalon 345 - 460
NAK 55 < 41 0.10 D 0.45 D TLN-Exalon 600 - 1200
NAK 80 < 41 0.10 D 0.40 D TLN-Exalon 600 - 1200
4130 - 4150 < 41 0.10 D 0.45 D TLN-Exalon 600 - 1200
Finkl FX1 & 2
0.12 D 0.45 D TLN-Exalon 800 - 1500
PX5
0.12 D 0.45 D TLN-Exalon 1200 - 1500
Gray Cast Iron / GG < 41 0.20 D 0.75 D TLN-Exalon 1150 - 3000

Cast Iron  / GGG

41+ 0.06D 0.40 D TLN-Exalon 820 - 1300
400 series stainless < 41 0.10 D 0.45 D TLN-Exalon 600 - 3000
400 series stainless 41-54 0.08 D 0.40 D TLN-Exalon 600 - 1200
300 series stainless < 41 0.10 D 0.45 D TLN-Exalon 345 - 800
CPM 9V & 10V < 41 0.10 D 0.40 D TLN-Exalon 600 - 1200
CPM 9V & 10V 41+ 0.06 D 0.35 D TLN-Exalon 350 - 800
Titanium (6Al 4V)
0.10 D 0.45 D TLN-Exalon 600 - 1200

tip-cutting   slope-cutting   side-cutting
     

Recommended Chip Load (Feed per Tooth fz ) with Moldstar Ball Nose End Mills Series "BI..EX"

Tool Number Cutter Ø D (inch) Die & Mold Steel 30 - 40 HRc Die & Mold Steel 41 - 54 HRc Die & Mold Steel 55 - 63 HRc
Roughing Finishing Roughing Finishing Roughing Finishing
BI .020 EX .020 .0004- .0005 .0003- .0004 .0003- .0004 .00024- .00032 .00024- .00032 .0002- .00024
BI .031 EX .031 .0006- .0008 .0006- .0006 .0006- .0006 .0004- .0005 .0004- .0005 .0003- .0005
BI .062 EX .062 .0012- .0016 .0010- .0012 .0010- .0012 .0007- .0010 .0007- .0010 .0005- .0007
BI .093 EX .093 .0019- .0023 .0015- .0019 .0015- .0019 .0011- .0015 .0011- .0015 .0007- .0011
BI .125 EX .125 .0025- .0031 .0020- .0025 .0020- .0025 .0015- .0020 .0015- .0020 .0010- .0015
BI .187 EX .187 .0037- .0047 .0030- .0037 .0030- .0037 .0022- .0030 .0022- .0030 .0015- .0022
BI .250 EX .250 .0050- .0063 .0040- .0050 .0040- .0050 .0030- .0040 .0030- .0040 .0020- .0030
BI .312 EX .312 .0062- .0078 .0050- .0062 .0050- .0062 .0037- .0050 .0037- .0050 .0025- .0037
BI .375 EX .375 .0075- .0095 .0060- .0075 .0060- .0075 .0045- .0060 .0045- .0060 .0030- .0045
BI .437 EX .437 .0087- .0110 .0070- .0088 .0070- .0088 .0052- .0070 .0052- .0070 .0035- .0052
BI .500 EX .500 .0100- .0125 .0080- .0100 .0080- .0100 .0060- .0080 .0060- .0080 .0040- .0060

Note: The recommended feed per tooth (fz) values shown in Table 2 are good starting values for HSC and hard milling with Moldstar ball nose tools. Specific application parameters may require lower fz values or may enable higher values.

Recommended Range of Spindle Speeds (RPM / min1)

Tool Number Cutter Ø D (inch) Die & Mold Steel 30 - 40 HRc Die & Mold Steel 41 - 54 HRc Die & Mold Steel 55 - 63 HRc
475-1200 SFM 1000+ SFM 460-800 SFM 720+ SFM 450-800 SFM 720+ SFM
Roughing & Semi-Finish Finish Machining Roughing & Semi-Finish Finish Machining Roughing & Semi-Finish Finish Machining
BI .020 EX .020 20,000-40,000+ 20,000-40,000+ 20,000-40,000+ 20,000-40,000+ 20,000-40,000+ 20,000-40,000+
BI .031 EX .031 20,000-40,000+ 20,000-40,000+ 20,000-40,000+ 20,000-40,000+ 20,000-40,000+ 20,000-40,000+
BI .062 EX .062 20,000-40,000+ 20,000-40,000+ 20,000-40,000+ 20,000-29,700+ 20,000-40,000+ 20,000-40,000+
BI .093 EX .093 19,500-40,000+ 20,000-40,000+ 20,000-29,500 20,000-35,000+ 18,000-32,800 20,000-29,500+
BI .125 EX .125 14,500-36,650 20,000-30,100+ 20,000-22,000 20,000-23,400+ 13,400-24,450 20,000-22,000+
BI .187 EX .187 9,700- 24,500 20,000+ 9,400-16,350 14,700+ 9,000-16,300 14,700+
BI .250 EX .250 7,250- 18,350 15,000+ 7,000-12,250 11,000+ 6,700-12,200 11,000+
BI .312 EX .312 5,800- 14,700 12,000+ 5,600-9,800 8,500+ 5,400-9,800 8,800+
BI .375 EX .375 4,850- 12,250 10,000+ 4,650-8,150 7,300+ 4,500-8,150 6,300+
BI .437 EX .437 4,150- 10,500 8,600+ 4,000-7,000 6,300+ 4,850-7,000 7,300+
BI .500 EX .500 3,650- 9,200 7,500+ 3,500-6,100 5,500+ 3,350-6,100 5,500+

Note: If the lowest recommended spindle speed (RPM) in table 3 is higher than the machine¹s capability, use the maximum spindle speed available on the machine.

Recommendations are for most die / mold steels. Certain tough to machine steels use lower values: see Table 1 for specific cutting speed values or consult our data base.

Specific application parameters may allow higher spindle speeds than recommended; please check with our application specialists for specific case parameter recommendations.

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Aggressive Recommendations for HSC Milling with Moldstar Ball Nose End Mills (Metric)

  1. Prerequisites: Maximum tool extension length to tool shank diameter L / D = 5 / 1. Use a rigid machine, part and set-up.
  2. For finishing with small step-over / pick feed (ae), use a feed per tooth (fz) equal to step-over: fz = ae (Small step-over is defined as ae = 2% of tool diameter D or less).
  3. On longer tool extension (max. L / shank 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 (9 -10% concentration). This will lubricate and not only cool the cutting edge for longer tool life, reduced chip welding and better the finish. Vegetable based oil mist works best in MQL / mist use. For gray cast iron use air or coolant. For all other die/mold materials use air-mist (MQL) or air blow, air blow only over 40 HRc.

The recommendations are for aggressive cutting with Moldstar ball nose tools and coatings as shown in table 1 and tool engagement shown below. When tip cutting only on flat surfaces, feed rate and spindle speed may be increased by up to 30%. For other materials or for specific application cases, contact the factory with as much detail as possible.

Work material Specifications

USA / W.-Nr. / JIS

Material Hardness

HRc

Cutting depth ap

maximum

Cutting width ae

maximum

 Recommended Coating type Recommended Cutting Speed Range at D
Vc(m/minute)
H13 / 1.2344 / SKD61 < 41 0.10 D 0.45 D TLN-Exalon 244 - 365
H13 / 1.2344 / SKD61 41-54 0.06 D 0.40 D TLN-Exalon 244 - 365
H13 / 1.2344 / SKD61 55 + 0.05 D 0.35 D TLN-Exalon 185
A2 / 1.2363 / SKD12 < 41 0.10 D 0.40 D TLN-Exalon 244 - 365
A2 / 1.2363 / SKD12 41-54 0.06 D 0.40.D TLN-Exalon 183 - 244
A2 / 1.2363 / SKD12 55 + 0.05 D 0.35 D TLN-Exalon 183 - 244
P 20 / 1.2330 < 41 0.10 D 0.45 D TLN-Exalon 244 - 365
P 20 / 1.2330 41-54 0.06 D 0.40 D TLN-Exalon 183 - 244
D 2 / 1.2379 / SKD11 < 41 0.10 D 0.45 D TLN-Exalon 183 - 244
D 2 / 1.2379 / SKD11 41-54 0.06 D 0.40 D TLN-Exalon 183 - 244
D 2 / 1.2379 / SKD11 55 + 0.05 D 0.35 D TLN-Exalon 105 - 140
NAK 55 < 41 0.10 D 0.45 D TLN-Exalon 183 - 365
NAK 80 < 41 0.10 D 0.40 D TLN-Exalon 183 - 365
Gray Cast Iron / GG < 41 0.20 D 0.75 D TLN-Exalon 350 -900

Cast Iron  / GGG

41+ 0.06D 0.40 D TLN-Exalon 250 - 400
400 series stainless < 41 0.10 D 0.45 D TLN-Exalon 183 - 915
400 series stainless 41-54 0.08 D 0.40 D TLN-Exalon 183 - 365
300 series stainless < 41 0.10 D 0.45 D TLN-Exalon 105 - 244
4140 / 1.7225 / SCM440 < 41 0.06 D 0.35 D TLN-Exalon 183 - 365
Titanium (6Al 4V)
0.10 D 0.45 D TLN-Exalon 183 - 365

tip-cutting   slope-cutting   side-cutting
     

Recommended Chip Load (Feed per Tooth fz ) with Moldstar Ball Nose End Mills Series "BM..EX"

ToolNumber Cutter Ø D (mm) Die & Mold Steel 30 - 40 HRc Die & Mold Steel 41 - 54 HRc Die & Mold Steel 55 - 63 HRc
Roughing Finishing Roughing Finishing Roughing Finishing
BM0.5 EX 0.5 0.010- 0.013 0.008- 0.010 0.008- 0.010 0.006- 0.008 0.006- 0.008 0.004- 0.006
BM1.0 EX 1.0 0.020- 0.025 0.016- 0.020 0.016- 0.020 0.012- 0.016 0.012- 0.016 0.008- 0.012
BM1.5 EX 1.5 0.030- 0.038 0.024- 0.030 0.024- 0.030 0.018- 0.024 0.018- 0.024 0.012- 0.018
BM2.0 EX 2.0 0.040- 0.050 0.032- 0.040 0.032- 0.040 0.024- 0.032 0.024- 0.032 0.016- 0.024
BM3.0 EX 3.0 0.060- 0.075 0.048- 0.060 0.048- 0.060 0.036- 0.048 0.036- 0.048 0.024- 0.036
BM4.0 EX 4.0 0.080- 0.100 0.064- 0.080 0.064- 0.080 0.048- 0.064 0.048- 0.064 0.032- 0.048
BM5.0 EX 5.0 0.100- 0.125 0.080- 0.100 0.080- 0.100 0.060- 0.080 0.060- 0.080 0.040- 0.060
BM6.0 EX 6.0 0.120- 0.150 0.096- 0.120 0.096- 0.120 0.072- 0.096 0.072- 0.096 0.048- 0.072
BM8.0 EX 8.0 0.160- 0.200 0.128- 0.160 0.128- 0.160 0.096- 0.128 0.096- 0.128 0.064- 0.096
BM10.0 EX 10.0 0.200- 0.250 0.160- 0.200 0.160- 0.200 0.120- 0.160 0.120- 0.160 0.080- 0.120
BM12.0 EX 12.0 0.240- 0.300 0.192- 0.240 0.192- 0.240 0.144- 0.192 0.144- 0.192 0.096- 0.144
BM16.0 EX 16.0 0.320- 0.400 0.256- 0.320 0.256- 0.320 0.192- 0.256 0.192- 0.256 0.128- 0.192

Note: The recommended feed per tooth (fz) values shown in Table 2 are good starting values for HSC and hard milling with Moldstar ball nose tools. Specific application parameters may require lower fz values or may enable higher values.

Recommended Range of Spindle Speeds (RPM / min1)

ToolNumber Cutter Ø D (mm) Die & Mold Steel 30 - 40 HRc Die & Mold Steel 41 - 54 HRc Die & Mold Steel 55 - 63 HRc
145-365m Vc 300+m Vc 140-244m Vc 220+m Vc 135-244m Vc 220+m Vc
Roughing Semi-Finish Finish Machining Roughing Semi-Finish Finish Machining Roughing Semi-Finish Finish Machining
BM0.5 EX 0.5 20,000- 40,000+ 20,000- 40,000+ 20,000- 40,000+ 20,000- 40,000+ 20,000- 40,000+ 20,000- 40,000+
BM1.0 EX 1.0 20,000- 40,000+ 20,000- 40,000+ 20,000- 40,000+ 20,000- 40,000+ 20,000- 40,000+ 20,000- 40,000+
BM1.5 EX 1.5 20,000- 40,000+ 20,000- 40,000+ 20,000- 40,000+ 20,000- 29,700+ 20,000- 40,000+ 20,000- 29,700+
BM2.0 EX 2.0 20,000- 40,000+ 20,000- 40,000+ 20,000- 38,800 20,000- 35,000+ 20,000- 38,800 20,000- 35,000+
BM3.0 EX 3.0 15,300- 38,700 20,000- 31,850+ 14,850- 25,900 20,000- 23,400+ 14,300- 25,900 20,000- 23,350+
BM4.0 EX 4.0 11,500- 29,000 20,000- 23,800+ 11,100- 19,400 17,500+ 10,700- 19,400 17,500+
BM5.0 EX 5.0 9,200- 23,200 19,000+ 8,900- 15,500 14,000+ 8,500- 15,500 14,000+
BM6.0 EX 6.0 7,700- 19,350 15,900+ 7,400- 12,950 11,650+ 7,150- 12,950 11,650+
BM8.0 EX 8.0 5,750- 14,500 11,900+ 5,550- 9,700 8,750+ 5,350- 9,700 8,750+
BM10.0 EX 10.0 4,600- 11,600 9,550+ 4,450- 7,750 7,000+ 4,300- 7,760 7,000+
BM12.0 EX 12.0 3,850- 9,700 7,950+ 3,700- 6,500 5,800+ 3,550- 6,500 5,800+
BM16.0 EX 16.0 2,850- 7,250 5,950+ 2,750- 4,850 4,350+ 2,650- 4,850 4,350+

Note: If the lowest recommended spindle speed (RPM) in table 3 is higher than the machine¹s capability, use the maximum spindle speed available on the machine.

Recommendations are for most die / mold steels. Certain tough to machine steels use lower values: see Table 1 for specific cutting speed values or consult our data base.

Specific application parameters may al