In modern mechanical processing, milling is one of the most widely used operations for producing high-precision metal parts.
For this operation, end mills are used, a type of extremely versatile cutting tool, capable of processing a wide variety of materials and geometries.
These cutters can be made of high-speed steel (HSS) or cemented carbide (tungsten carbide), with each variant having specific advantages depending on the application.
What is an end mill
An end mill is a rotary tool with multiple cutting edges, used for material removal by milling.
Main characteristics:
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it has teeth on the periphery and on the face
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can perform side and face milling
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allows plunging into the material
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is available in several variations of diameter, number of teeth, and geometry
These mills are frequently used for:
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contour milling
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creating grooves
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roughing
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finishing
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pocket milling
Depending on the material they are made from, end mills are divided into two main categories: HSS and solid carbide.
HSS (High Speed Steel) End Mills
HSS (High-Speed Steel) end mills are among the most traditional tools used in metalworking.
Advantages
✔ lower acquisition cost
✔ good resistance to shocks and vibrations
✔ suitable for less rigid machine tools
✔ easy to resharpen
Typical Use
HSS end mills are frequently used for:
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soft steels
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aluminum
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non-ferrous materials
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general milling operations
They are especially suitable for moderate cutting speeds and applications where the rigidity of the machine-tool system is not very high.
Solid Carbide End Mills
Tungsten carbide (solid carbide) end mills represent the modern standard in high-performance CNC machining.
Carbide is a composite material primarily composed of:
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tungsten carbide
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cobalt binder
This material offers much greater hardness and temperature resistance than HSS.
Advantages
✔ very high wear resistance
✔ allows much higher cutting speeds
✔ high dimensional stability
✔ longer tool life
✔ superior precision
Carbide end mills are especially used for:
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alloy steels
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treated steels
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stainless steel
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cast iron
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difficult alloys
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serial CNC production
Main difference between HSS and carbide end mills
| Characteristic | HSS Mills | Carbide Mills |
|---|---|---|
| Hardness | medium | very high |
| Cutting speeds | moderate | very high |
| Temperature resistance | limited | very high |
| Cost | lower | higher |
| Tool life | shorter | much longer |
In modern CNC production, solid carbide end mills are preferred due to their superior productivity and stability.
End mill sharpening
An important aspect in using these tools is that end mills can be reconditioned multiple times, significantly reducing production costs.
Through specialized CNC regrinding services, such as ToolRestore from Sefira, the following operations can be performed:
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regrinding of cutting edges
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honing of edges
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industrial cleaning
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PVD recoating
Through reconditioning, a carbide end mill can be reused in production with:
📉 savings of 50–80% compared to a new tool
📈 performance similar to new tools
This makes reconditioning an economical and sustainable solution for companies in the mechanical processing industry.
Conclusion
End mills are among the most important tools used in CNC milling.
The choice between HSS and carbide depends on the application, the material being processed, and the desired performance.
In modern production, carbide end mills offer superior productivity and tool life, and through reconditioning, they can be used for multiple life cycles, significantly reducing tooling costs.
📩 If you have worn carbide or HSS end mills, the SEFIRA team can help you with professional reconditioning services.
info@sefira.ro
+40 712 333 902