Tool Selection Guide
Choose the right cutter geometry, substrate, and coating for your material and operation. Better tool selection means fewer tool changes, longer life, and better surface finish.
Operation → Tool type
| Operation | Tool type | Geometry recommendation | Coating |
|---|---|---|---|
| Aluminum roughing | Solid carbide end mill | 3 flutes, high helix 35–45°, polished flutes | Uncoated or ZrN |
| Aluminum finishing | Ball nose / bull end mill | 2–3 flutes, sharp edge | Uncoated |
| Steel roughing | Roughing end mill (chipbreaker) | 4 flutes, 30° helix | TiCN or AlCrN |
| Steel finishing | Square end mill / ball nose | 3–4 flutes, sharp edge prep | AlCrN |
| Stainless milling | Variable helix end mill | 3–4 flutes, unequal helix for chatter | AlCrN or TiAlN |
| Cast iron | End mill / face mill | 4–6 flutes, positive rake | TiN or uncoated |
| Titanium | Variable helix, high shear | 3 flutes, polished, sharp edge | TiAlN (Al-rich) |
| Slotting / plunge | Plunge end mill | 2–3 flutes, center-cutting | TiCN |
| Thread milling | Thread mill | Single-profile or full-profile | TiCN |
| Face milling | Face mill (insert) | Positive rake, 45° lead angle | Insert grade per material |
Key selection principles
Flute count: fewer flutes = more chip room (for aluminum, soft materials, slotting). More flutes = higher feed rate (for steel, finishing, small features).
Helix angle: higher helix (35–45°) gives shearing action in aluminum and stainless. Lower helix (20–30°) is stronger for heavy roughing in steel.
Coating matching: TiN for general steel (low heat). TiCN for abrasive materials. AlCrN/TiAlN for high-heat cutting (stainless, titanium, hardened steel). Uncoated for aluminum to prevent built-up edge.
Rigidity first: always use the shortest tool that reaches the feature. A 10 mm tool at 15 mm protrusion outlasts the same tool at 30 mm by 3–5×.