Tungaloy TungForce-Feed vs DoFeed: High-Feed Milling Compared
Tungaloy offers two distinct high-feed milling platforms: TungForce-Feed and DoFeed. Both are designed to maximize metal removal rates by using shallow depths of cut with high feed per tooth, but they target different application ranges and material groups. This article provides a detailed technical comparison to help you select the right system for your milling operations.
High-Feed Milling Principles
High-feed milling operates on a simple principle: use a very small axial depth of cut (typically 0.5-3.0 mm) combined with a high feed per tooth (0.5-2.5 mm/tooth) to achieve metal removal rates that rival or exceed conventional milling. The shallow depth of cut directs cutting forces predominantly in the axial direction (into the spindle), reducing radial forces that cause deflection and vibration.
This approach is particularly effective for:
- Long-overhang milling where radial deflection causes chatter
- Roughing of hardened steels and difficult-to-machine materials
- Mold and die cavity roughing with deep pockets
- Aerospace structural components in titanium and Inconel
TungForce-Feed System Overview
TungForce-Feed is Tungaloy’s premium high-feed milling platform, designed for productivity in steel, stainless steel, and cast iron. It uses a double-sided insert with 4 cutting edges, maximizing economy per part.
Key specifications:
- Insert types: LNMU 0503 (small), LNMU 0704 (medium), LNMU 1005 (large)
- Cutter diameters: 16-125 mm
- Max axial depth of cut: ap = 1.0 mm (LNMU 0503), 2.0 mm (LNMU 0704), 3.0 mm (LNMU 1005)
- Feed per tooth: fz = 0.5-1.5 mm/tooth
- Effective cutting edge angle: 12-15 degrees (very low entry angle)
- Cutting edges per insert: 4 (double-sided)
DoFeed System Overview
DoFeed is Tungaloy’s versatile high-feed and high-efficiency milling platform. It uses a single-sided insert with a larger cutting edge angle than TungForce-Feed, allowing slightly deeper cuts while maintaining high feed rates.
Key specifications:
- Insert types: DOMT 0703 (small), DOMT 1004 (medium), DOMT 1305 (large)
- Cutter diameters: 20-160 mm
- Max axial depth of cut: ap = 1.5 mm (DOMT 0703), 2.5 mm (DOMT 1004), 4.0 mm (DOMT 1305)
- Feed per tooth: fz = 0.3-1.2 mm/tooth
- Effective cutting edge angle: 18-22 degrees
- Cutting edges per insert: 2-4 depending on size
Direct Comparison Table
| Parameter | TungForce-Feed | DoFeed |
|---|---|---|
| Insert geometry | Double-sided, 4 edges | Single/double-sided, 2-4 edges |
| Entry angle | 12-15 degrees | 18-22 degrees |
| Max depth of cut | 3.0 mm (LNMU 1005) | 4.0 mm (DOMT 1305) |
| Max feed per tooth | 1.5 mm/t | 1.2 mm/t |
| Axial cutting force direction | Strong axial bias (90%+ axial) | Moderate axial bias (75-85% axial) |
| Radial force level | Very low | Low to moderate |
| Surface finish on floor | Rough (Ra 3.2-6.3 um) | Semi-rough (Ra 2.5-5.0 um) |
| Cost per cutting edge | Lower (4 edges, double-sided) | Moderate (2-4 edges) |
| Best for long overhangs | Excellent (L/D > 5) | Good (L/D up to 4) |
| Versatility | Specialized (high-feed only) | Versatile (high-feed + ramping + helical) |
Grade Options for Both Systems
| Grade | Coating | ISO Class | Speed Vc (m/min) | Best Application |
|---|---|---|---|---|
| AH3225 | PVD TiAlN | P20-P35, M15-M30 | 120-280 | General steel milling, both systems |
| AH3130 | PVD TiAlN | P25-P40 | 100-220 | Interrupted milling, tough conditions |
| AH725 | PVD TiAlN | M15-M25, S10-S20 | 60-160 | Stainless steel and superalloys |
| T9015 | CVD Al2O3-TiCN | P10-P25, K10-K25 | 180-350 | Cast iron, continuous milling |
| TH3505 | CVD Al2O3 | K15-K30 | 150-300 | Gray and ductile iron |
Cutting Parameter Comparison: AISI 4140 Steel
| System | Insert | Cutter Dia. | ap (mm) | fz (mm/t) | Vc (m/min) | Table Feed (mm/min) | MRR (cm3/min) |
|---|---|---|---|---|---|---|---|
| TungForce-Feed | LNMU 0704 | 32 mm (3 teeth) | 1.5 | 1.0 | 200 | 955 | 45.8 |
| DoFeed | DOMT 1004 | 40 mm (3 teeth) | 2.0 | 0.8 | 200 | 764 | 61.1 |
| TungForce-Feed | LNMU 1005 | 50 mm (4 teeth) | 2.5 | 1.2 | 180 | 917 | 114.6 |
| DoFeed | DOMT 1305 | 63 mm (5 teeth) | 3.0 | 0.9 | 180 | 573 | 108.3 |
Application Selection Guide
Choose TungForce-Feed when:
- Long-overhang milling (L/D ratio above 4) is required
- Radial cutting forces must be minimized (thin walls, weak fixtures)
- Maximum feed per tooth is desired for rapid stock removal
- The operation is pure high-feed face milling or pocket roughing
- Cost per cutting edge is critical (4 usable edges per insert)
- Machining hardened steels (45-55 HRC) where shallow cuts are mandatory
Choose DoFeed when:
- Deeper axial cuts are needed (above 2.5 mm per pass)
- The operation includes ramping, helical interpolation, or plunging
- Better floor surface finish is needed for the semi-finishing pass
- The machine has limited table feed rate (DoFeed needs lower feed rates)
- Multi-function capability is needed from a single tool (face milling + ramping)
- Larger diameter cutters are used (above 80 mm) where deeper cuts are practical
Real-World Application Examples
Mold base roughing (P20 tool steel, 32 HRC): TungForce-Feed with LNMU 0704, AH3225 grade, 32 mm cutter at ap=1.5 mm, fz=1.0 mm/t, Vc=180 m/min achieves 42 cm3/min MRR with excellent tool life of 180 minutes. The low radial forces allow milling near thin walls without deflection.
Aerospace bracket pocketing (Ti-6Al-4V): DoFeed with DOMT 1004, AH725 grade, 40 mm cutter at ap=2.0 mm, fz=0.5 mm/t, Vc=60 m/min provides 24 cm3/min MRR. The DoFeed insert handles the ramping entry into the pocket floor without the vibration that TungForce-Feed would produce at this depth.
Ductile iron gearbox housing (GGG-50): TungForce-Feed with LNMU 1005, T9015 grade, 63 mm cutter at ap=2.5 mm, fz=1.2 mm/t, Vc=250 m/min achieves 190 cm3/min MRR. The high productivity and low cost per edge make TungForce-Feed ideal for high-volume cast iron roughing.
Conclusion
Both TungForce-Feed and DoFeed deliver exceptional productivity in high-feed milling, but they serve different niches. TungForce-Feed is the specialist for maximum feed rates with minimum radial forces, ideal for long-overhang and thin-wall milling. DoFeed is the more versatile platform that handles deeper cuts and multi-axis entry strategies. Many shops benefit from stocking both systems, using TungForce-Feed for pure roughing passes and DoFeed for operations requiring ramping or deeper axial engagement.
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