End Mill Icon Glossary

Number of Flutes Workpiece

Z3 Material Group

Center Cutting Steels

P
Cutting Calculations And Definitions Metric U.S.
Width of cut, radial depth
ae = (mm) (inch)
Stainless Steels of cut
Lengths M Depth of cut, axial depth
ap = (mm) (inch)
of cut
Dc = Cutter diameter (mm) (inch)
Cast Iron
Coatings K f = Feed per revolution (mm/rev) (IPR)
fz = Feed per tooth (mm/tooth) (IPT)
zn = Number of teeth Number
ALtima® ALtima® TiAlN Special Alloys
n = RPM (rev/min) (rev/min)
Xtreme S
Q = Metal removal rate (cm /min)
3
(in3/min)
vc = Cutting speed (m/min) (SFM)
TiCN TiN Fordlube Hardened Steels vf = Feed speed (mm/min) (IPM)
H (35-65Rc)
Dw = Working diameter (mm) (inch)

CERAedge® Non-Ferrous
N Formulas
Inch
RPM (n) = SFM (vc) x 3.82/Tool Diam.
30°
Helix Angle IPM (vf) = RPM (n) x IPR (f)
Conversion Inch to Metric
Coolant Maximum
SFM (vc) to m/min (vc) = SFM (vc) x .3048
IPM (vf) to mm/min (vf) = IPM (vf) x 25.4
Ball Nose Max. Coolant Metric
RPM (n) = m/min (vc) x 318.057/Tool Diam.
Coolant Minimal mm/min (vf) = RPM (n) x mm/Revolution (f).
Conversion Metric to Inch
Neck Relief MMS Coolant m/min (vc) to SFM (vc) = (m/min)/.3048
N mm/min (vf) to IPM (vf) = (mm/min)/25.4
N

Corner Radius

Shank

Shank/DIN
HB

DIN6535 Safety Note

Always wear the appropriate personal protective equipment such as safety
glasses and protective clothing when using solid carbide or HSS cutting
Chipbreaker tools. Machines should be fully guarded. Technical data provided should be
considered advisory only as variations may be necessary depending on the
Chipbreaker particular application.

Technical data provided should be considered advisory only as variations may be necessary depending on the particular application.
310 M.A. Ford® Phone: 800-553-8024 or 563-391-6220 • email: sales@maford.com • www.maford.com
 End Mill Troubleshooting

PROBLEM POSSIBLE CAUSE POSSIBLE SOLUTION

Speed too high Reduce the cutting speed RPM’s (n).

Improper feed speed (too slow) Increase feed per tooth (fz).
Try 90-100 SFM (vc) with multi-fluted tool
Hard workpiece material > 55 Rc
(5 flutes+). Use ALtima® 52 hard coating.

Change feed speed to change chip size or clear

Recutting Chips
chips with coolant or air pressure.
Excessive Flank Wear
Ensure you are climb milling unless workpiece
material has hard/abrasive outer skin or high
Milling Strategy
impact tool steel like D2, then conventional milling
technique is preferred for breakthrough (see pg 314).
Change to correct cutting angle, tilt tool at 15
Improper cutting angle
degrees.
Too low a primary relief angle Change to larger relief angle.

PROBLEM POSSIBLE CAUSE POSSIBLE SOLUTION

Implementing corner radius on tool adds strength

No Corner Radius
and increases tool life.
Speed too high Reduce the cutting speed RPM’s (n).
Check tool runout in holder/spindle, <.0003"
Excessive Corner Wear (.0076mm) desired. Hand ground flats can be
Tool Runout
suspect and common cause. Use collet, milling
chuck, or shrink fit holders if possible.
Ensure you are using shortest OAL possible,
Tool Overhang stub tool in holder. Utilize stronger necked tool
for longer reaches.

PROBLEM POSSIBLE CAUSE POSSIBLE SOLUTION

Technical Information
Use shortest end mill available, hold shank deeper
Lack of rigidity (tool) in holder, investigate for tool slippage. Use short
gage length holder.
Lack of rigidity (workpiece) Tighten workpiece fixture - a common problem.
Feed too high Decrease feed per tooth (fz)
Decrease feed per tooth (fz) on first pass through
Feed to high on first pass workpiece skin or reduce radial width of cut (ae)
first pass.
Reduce FPT on entry - implement radius in or
Part Entry sweeping entrances - avoid 90º (perpendicular)
entry.
Ensure you are climb milling unless workpiece
material has hard/abrasive outer skin or high impact
Milling Strategy
Cutting Edge Chipping tool steel like D2, then conventional milling
Icon Glossary / Troubleshooting
technique is preferred for breakthrough (see pg 314).
Ensure you are using shortest OAL possible,
Tool Overhang stub tool in holder. Utilize stronger necked tool
for longer reaches.
Check tool runout in holder/spindle, <.0003"
TuffCut®

(.0076mm) desired. Hand ground flats can be

Tool Runout
suspect and common cause. Use collet, milling
chuck, or shrink fit holders if possible.
Not enough rigidity of machine tool
Change rigid machine tool or holder.
& holder
Ensure tool has proper edge prep for
Cutting Edge Prep
workpiece material.
Teeth too sharp Change to lower cutting angle, primary relief.

Technical data provided should be considered advisory only as variations may be necessary depending on the particular application.
For product information, call your local distributor. 311
 End Mill Troubleshooting Continued

PROBLEM POSSIBLE CAUSE POSSIBLE SOLUTION

Lack of rigidity (workpiece) Tighten workpiece fixture - a common problem.

Speed too low Increase the cutting speed RPM’s (n).
Feed too high Decrease feed per tooth (fz).
Reduce width of cut, radial depth of cut (ae) & depth of
Heavy depth of cut
cut, axial depth of cut (ap).
Reduce FPT on entry - implement radius in or sweeping
Part Entry
entrances - avoid 90º (perpendicular) entry.
Review tool path and ensure there are no arbitrary
moves, extreme arc of engagement increases &
Milling Strategy
Breakage undesirable situations for the tool. Keep constant radial
engagement. See tool path diagrams on page 317.
Ensure you are using shortest OAL possible, stub tool in
Tool Overhang
holder. Utilize stronger necked tool for longer reaches.
Check tool runout in holder/spindle, <.0003" (.0076mm)
desired. Hand ground flats can be suspect and common
Tool Runout
cause. Use collet, milling chuck, or shrink fit holders
if possible.
Recondition at earlier stage. Factory recondition
Excessive edge wear service is recommended. See M.A. Ford’s® Red box
reconditioning program on page 471.

PROBLEM POSSIBLE CAUSE POSSIBLE SOLUTION

Utilize proper tool coating for workpiece material being

Chip Welding to cutting edge
cut. Climb mill preferred.
Feed too low Increase feed per tooth (fz).
Built Up Edge (BUE)
Speed too low Increase the cutting speed RPM’s (n).
Add coolant or readjust coolant flow, use through tool
Coolant Strategy
coolant if available. Check coolant mixture concentration.

PROBLEM POSSIBLE CAUSE POSSIBLE SOLUTION

Insufficient chip room Use end mill with fewer flutes.

Feed too high Decrease feed per tooth (fz).
Reduce width of cut, radial depth of cut (ae) & depth of
Heavy depth of cut
Chip Packing cut, axial depth of cut (ap).
Apply more coolant to flush chips. Use air pressure or op.
Not enough coolant
stop to clear chips away.
Large heavy chip Utilize chipbreaker style tool to cut chip size.

PROBLEM POSSIBLE CAUSE POSSIBLE SOLUTION

Feed too high Decrease feed per tooth (fz).

Speed too low Increase the cutting speed RPM’s (n).
Increase width of cut, radial depth of cut (ae) to stabilize
Too light width of cut
tool in cut.
Check tool runout in holder/spindle, <.0003" (.0076mm)
desired. Hand ground flats can be suspect and common
Poor Surface Finish Tool Runout
cause. Use collet, milling chuck, or shrink fit holders
if possible.
Built up Edge Use Flood Coolant.
Redirect/Evaluate coolant flush - or use fewer number
Recutting Chips
of flutes.
No end tooth concavity Add margin (touch primary with oilstone).

Technical data provided should be considered advisory only as variations may be necessary depending on the particular application.
312 M.A. Ford® Phone: 800-553-8024 or 563-391-6220 • email: sales@maford.com • www.maford.com
 End Mill Troubleshooting Continued

PROBLEM POSSIBLE CAUSE POSSIBLE SOLUTION

Lack of rigidity (workpiece) Tighten workpiece fixture - a common problem.

Use better machine tool, holder or change
Lack of rigidity (machine & holder) condition. Ask your M.A. Ford® representative
about BlueSwarf harmonic testing.
Check tool runout in holder/spindle, <.0003"
(.0076mm) desired. Hand ground flats can be
Tool Runout
suspect and common cause. Use collet, milling
chuck, or shrink fit holders if possible.
Speed too high Reduce the cutting speed RPM’s (n).
Chatter/Vibration Feed too low Increase feed per tooth (fz).
Chip too thin Utilize chip thinning adjustment multiplier.
Use smaller tools and generate corner radii
in pockets. Avoid tools that diameter matches
Arc of engagement violation
workpiece corner radius, or rough plunge
corners.
Ensure you are climb milling unless workpiece
material has hard/abrasive outer skin or high
Milling Strategy
impact tool steel like D2 then conventional
milling technique is preferred for breakthrough.

PROBLEM POSSIBLE CAUSE POSSIBLE SOLUTION

Ensure you are using shortest OAL possible,

Tool Overhang stub tool in holder. Utilize stronger necked tool
for longer reaches.
Increase diameter of end mill for higher
End mill Diameter
strength to length ratio.
Tool Deflection Higher number of flutes = larger core diameter
Increase number of flutes

Technical Information
= increased strength.
Feed too high Decrease feed per tooth (fz).
Too high width of cut Decrease width of cut, radial depth of cut (ae).
Climb milling can help reduce the amount of
Milling Strategy
deflection in some cases.

PROBLEM POSSIBLE CAUSE POSSIBLE SOLUTION

Add coolant or readjust coolant flow, use

Coolant Strategy through tool coolant if available. Check coolant
mixture concentration.
Tool Deflection See Tool Deflection above.
No Dimensional Accuracy Feed too high Decrease feed per tooth (fz).
(Wall Tapered)
Too high width of cut Decrease width of cut, radial depth of cut (ae).
Check tool runout in holder/spindle, <.0003"
(.0076mm) desired. Hand ground flats can be
Tool Runout
suspect and common cause. Use collet, milling
chuck, or shrink fit holders if possible.
Troubleshooting
TuffCut®

Technical data provided should be considered advisory only as variations may be necessary depending on the particular application.
For product information, call your local distributor. 313
 Milling Strategy
Comparison
®
®

Conventional Machining High Speed Machining (HSM)

• Reduced Axial Depths Of Cut • Increased Axial Depths Of Cut

(ap) - Normally 1 x Tool Diameter (ap) - up to 2 x Tool Diameter

• Higher Radial Depths Of Cut (ae) • Reduced Radial Depths Of Cut

- Normally 0.5 x Tool Diameter (ae) - 0.1/0.2 x Tool Diameter

• Lower Spindle Speed RPM (n) • Higher Spindle Speed RPM (n)

• Lower Feed Rate (vf) • Higher Feed Rate (vf)

(inch/min or mm/min) (inch/min or mm/min)

• Slower Machining Time • Faster Machining Time

• Low Metal Removal Rate • High Metal Removal Rate

(Q - in3/min or cm3/min) (Q - in3/min or cm3/min)

Contact Your Local M.A. Ford®

Representative For More Information On The Right
Milling Strategy For Your Application.

Technical data provided should be considered advisory only as variations may be necessary depending on the particular application.
314 M.A. Ford® Phone: 800-553-8024 or 563-391-6220 • email: sales@maford.com • www.maford.com
 Milling Strategy Comparison continued

Conventional High Speed

Tool Ø 12.0mm (.4724") 4 Flute Tool Ø 12.0mm (.4724") 5 Flute

vc - 150m/min (5,905 in/min) vc - 300m/min (11,811 in/min)

n - 3,975 RPM n - 8,000 RPM
fz - 0.06mm/z (.0024 in/z) fz - 0.15mm/z (.006 in/z)

Technical Information
vf - 954mm/min (37.6 in/min) vf - 6,000mm/min (240 in/min)

ap - 2 x 12.0mm (.4724") 1xD ap - 24.0mm (.945") 2xD

ae - 6.0mm (.2362") 0.5xD ae - 1.2mm (.047") 0.1xD

Metal Removal Rate (MRR) Metal Removal Rate (MRR)

68.7 cm3/min (4.2 in3/min) 172.8 cm3/min (10.5 in3/min)

Machining Time Machining Time

7 minutes 45 Seconds 3 minutes 35 Seconds Milling Strategy Comparison
TuffCut®

Contact Your Local M.A. Ford®

Representative For More Information On The Right
Milling Strategy For Your Application.

Technical data provided should be considered advisory only as variations may be necessary depending on the particular application.
For product information, call your local distributor. 315
 Radial Chip Thinning

During profile or side milling with a solid carbide end mill at 50% (ae) radial width of cut, the
chip formed is at full programmed thickness. When your radial depth of cut decreases to some-
thing less than 50%, the chip formed is not as thick. This is known as “radial chip thinning".
When less than 50% (ae) radial depths are used, it becomes necessary to increase your feed
to achieve full chip thickness. This means a higher programmed feed rate is needed to achieve
the recommended chip thickness.

Programmers and Machinists have a tendency to lower feed rate due to previous experience.
With the utilization of new programming methods, such as trochoidal and peel milling, manufac-
turers can increase productivity and tool life. These methods take advantage of much deeper
(ap) axial cuts with less (ae) radial width of cut. With these methods, it’s possible to run higher
surface footages (SFM or m/min) along with these higher feed rates (IPM or mm/min) because
less heat is generated at the cutting zone. Plus, you’re utilizing chip thinning.

With the introduction of M.A. Ford®’s variable pitch tools, harmonics have virtually been elimi-
nated, thus easing Programmers and Machinists fears of previous experiences. Advancements
in our hard coatings enable our tools to withstand 900 degrees F, thus eliminating heat concerns.
In addition, machine tools have advanced greatly to take advantage of these new methods.
Use the following chart as a reference to increase feed rates by multiplying recommended
feed rate by the increase feed factor, according to your (ae) radial depth of cut as % of (Dc)
cutter diameter.

(ae) Radial Depth of

Increase Feed
Cut as to % of (Dc)
Factor
Cutter Diameter
30% 1.10
25% 1.20
20% 1.20
15% 1.41
10% 1.80
7% 2.00
5% 2.30
3% 2.93
2% 3.60
1% 5.00

DC DC

X X X
X
ae
ae

Technical data provided should be considered advisory only as variations may be necessary depending on the particular application.
316 M.A. Ford® Phone: 800-553-8024 or 563-391-6220 • email: sales@maford.com • www.maford.com
 Tool Engagement Angle

Sometimes referred to as “Arc of Engagement", this is the degrees of engagement the end
mill will contact the part during cut depths in the radial direction. Ideally you would like to
engage the end mill at a constant engagement angle of 30-40 degrees. At this degree of
engagement the tool will perform best because of acceptable loading while not exceeding
deflection limits.

As the tool travels around the geometrical shape of the part features, it will encounter areas
where it could exceed the acceptable engagement angle. Software manufacturers have cre-
ated methods to calculate algorithms to avoid these situations. One such case would be the
entry into a pocket corner. At 50% radial depth of cut (ae), the cutter runs along the pocket
side with a tool engagement angle of 90 degrees. As it enters the corner, it can quickly jump
to 180 degrees as shown in the example below.

z
y z
x y

Technical Information
x

Radial Chip Thinning / Tool Engagement

z
y
x
TuffCut®

At this intersection, large engagement would cause tool chatter and even breakage. Using
CAD CAM software to generate the corner avoids an abrupt stop and change of direction.
It also keeps a constant arc of engagement while providing smooth chatter free cutting and
long tool life.

Technical data provided should be considered advisory only as variations may be necessary depending on the particular application.
For product information, call your local distributor. 317
 Deflection

During the machining process, high cutting forces are directed on the end mill causing it
to deflect. How much the end mill deflects depends on cutting parameters, tool diameter,
tool stick out, and the elasticity coefficient (PSI) of the cutting tool material. The cutting tool
strength will vary from different suppliers. At M.A. Ford®, we use only raw material of the
highest quality and strength.

During roughing, deflection can be slightly higher than finishing. Deflection may be tolerable
when roughing because at some point you will come back and finish cut your part. On larger
carbide tools, deflection less than .001" (.025mm) is acceptable. However, on small micro
end mills, deflection of less than .0005" (.0127mm) is acceptable.

Depending whether you are conventional milling or climb milling, deflection will be in different
directions. With climb milling, deflection is in the direct opposite of the cut, but with conven-
tional milling its direction is more parallel with the cut. This difference in direction will impart
a different pattern finish on the wall of the workpiece. In climb milling, the tool engagement
lines are more vertical and distinct. With conventional milling, your chip starts out thin and
then gets thicker as your end mill continues through the cut; tool engagement lines are not
as distinctly vertical.

M.A. Ford® has designed computer software to perform the many calculations required to
determine tool deflection. All M.A. Ford® tools carry a Lot Number which can be traced back
to that tool’s DNA. With this information, we can plug the exact carbide TRS number into our
software. How does this benefit you? We can increase cutting parameters to the point of
maximum deflection, thus optimizing your operation parameters.
Please contact M.A. Ford®’s Tech Line (1-800-553-8024 or maftech@maford.com) with your
tooling application questions.

ISO 9001:2015 Certified

Technical data provided should be considered advisory only as variations may be necessary depending on the particular application.
318 M.A. Ford® Phone: 800-553-8024 or 563-391-6220 • email: sales@maford.com • www.maford.com
 Pocket Corners

Inside or pocket corners present a different challenge in two ways. First, if the corner radius
is proportionally smaller than the related pocket size, it is necessary to use a much smaller
diameter end mill to achieve the necessary radius. With a small diameter end mill there are
restrictions from a cut depth standpoint; a small end mill will deflect when axial depth of cut
(ap) exceeds the end mills limits and breakage can occur.

Secondly, to rough the pocket the programmer may use a much larger end mill to remove
large amounts of stock. If you plow into the rough corner with the small end mill, your tool
engagement angle can cause the small end mill to deflect and chip or break. To avoid these
problems, you must use one of two methods: peck milling or rest milling. Software packages
again ease this procedure by maintaining low tool engagement angle.

Peck milling is a series of axial plunge moves to remove much of the stock remaining in the
corner. Plunging directs forces axially on the machine spindle, thus eliminating radial force
and deflection. This is particularly beneficial for light duty machines.

Rest milling is a series of circular moves while traveling in the Z direction, very similar to heli-
cal milling. This removes the remaining stock much like trochoidal milling but with the addi-
tion of Z movements.

Peck Milling Rest Milling

Technical Information
Deflection / Pocket Corners
TuffCut®

z z
y y
x x

Technical data provided should be considered advisory only as variations may be necessary depending on the particular application.
For product information, call your local distributor. 319
 End Mill Terminology

Length of Cut (Flute Length) – Always

select the shortest Flute Length possible
for your application. By selecting the
shortest Flute Length, you can increase
rigidity and allow for higher feed rates.

End Mill Diameter – Always select

the largest diameter possible for your
milling operation. Increasing your
diameter by just 10%, can increase
your rigidity by 25%.

Helix Angle – Varies from 0 to 60 degrees.

Higher helix angles can increase the number
of teeth in a cut, and help in redirecting cutting
forces. This is beneficial in harder to machine
materials in particular. Changes in helix angle
can also greatly affect the flute form of an end
mill, and affect chip evacuation.

Web Thickness – The cross

section of the fluting
of the end mill. Larger webs
allow for more rigidity, while
smaller webs allow for better
chip evacuation. This feature is
highly dependent on the material
being machined.

Rake Angle – The measurement of the

curvature of the cutting edge in the face of
the flute. A high rake angle will cut more
aggressively, while a lower rake angle will
increase the strength of the cutting edge.

Primary Relief – The clearance directly

behind the cutting edge. High primary relief
angles will allow for more aggressive milling,
while lower relief angles will increase the
strength of the cutting edge. The primary
relief will also affect the wear on a cutting
edge. Lower primary relief angles can tend
to develop larger wear lands.

384 M.A. Ford® Phone: 800-553-8024 or 563-391-6220 • email: sales@maford.com • www.maford.com