How to Choose the Correct End Mill？

Choosing the right end mill greatly influences machining accuracy, surface finish, and production efficiency. Factors such as tool geometry, material hardness, flute design, and coating all impact the final result.

1. Choose the Right End Mill Type

Common types include:

• Flat End Mill – For slotting and side milling.

• Ball Nose End Mill – For 3D contouring.

• Corner Radius End Mill – Extended tool life in roughing.

• Aluminum End Mill – High sharpness, large chip space.

• Roughing End Mill – High stock removal.

• Thread End Mill – Thread milling operations.

• Taper / Micro / Chamfering / Deep Groove – Specialized applications.

2. Select End Mill Based on Workpiece Hardness

End mills are typically classified by HRC rating:

• HRC45 – Suitable for soft metals like aluminum, mild steel.

• HRC55 – For stainless steel and standard steel.

• HRC60 – For hardened steel, high wear applications.

• HRC65 – For extremely hard materials, finishing hardened molds.

3. Consider Flute Design

• 2 flutes – Aluminum, non-ferrous materials.

• 3 flutes – General steel cutting.

• 4 flutes and above – High rigidity, tungsten steel, finishing.

4. Coating Selection

• TiAlN / AlTiN – High heat resistance for steel.

• TiCN – Hard and smooth for stainless steel.

• Uncoated – Soft materials (aluminum, brass).

Selecting the proper end mill ensures longer tool life, smoother chip evacuation, and increased machining speed.