Face milling delivers the highest metal removal rates in milling. Maximizing MRR while maintaining tool life requires careful parameter selection.
Choosing Cutter Diameter
Rule: cutter diameter should be 1.4× the width of cut. For 100mm wide cut, use 140mm cutter. At full width engagement, average chip thickness drops sharply.
Lead Angle Effect
| Lead Angle | Use Case |
|---|---|
| 0° (square shoulder) | True 90° walls (F4042) |
| 45° | General face milling (M5009) |
| 60° (high-feed) | Maximum feed rate (F2010) |
| 75-88° (round insert) | Heavy roughing, mold cavity |
High-Feed Strategy
HFM uses very high feed (1-3 mm/tooth) at shallow axial depth (0.5-1.5mm). MRR exceeds traditional roughing by 50-100%. Tool: F2010 series or equivalent round-insert cutter.
Roughing Parameters by Material
| Material | Vc | Feed/tooth | Axial DOC |
|---|---|---|---|
| 1045 steel | 200-280 | 0.20-0.30 | 3-5mm |
| Stainless 304 | 120-180 | 0.15-0.25 | 2-4mm |
| Cast iron | 180-250 | 0.20-0.30 | 3-5mm |
| Aluminum | 500-1000 | 0.15-0.25 | 5-10mm |
Browse face milling cutters in our end mill catalog.
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