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How long should a carbide end mill last?
The lifespan of a carbide end mill depends on several factors, including the material being machined, cutting conditions, tool quality, and maintenance. Here's a general guideline:
Soft Materials (Aluminum, Plastics, Wood):
50–200 hours of cutting time (or more, if optimized).
Mid-Hard Materials (Steel, Stainless Steel, Titanium):
20–100 hours, depending on hardness and coolant use.
Hard Materials (Hardened Steel, Inconel, Titanium Alloys):
5–50 hours (more prone to wear and chipping).
Cutting Parameters:
Speed (SFM/RPM) – Excessive speed increases heat and wear.
Feed Rate (IPM/MMPM) – Too slow causes rubbing; too fast induces shock.
Depth of Cut (DOC) – Heavy cuts reduce tool life; light cuts may increase wear from work-hardening.
Material Being Machined:
Softer materials (e.g., aluminum) reduce wear, while harder metals (e.g., tool steel) accelerate degradation.
Abrasive composites (like CFRP) wear edges faster despite low hardness.
Tool Quality & Coating:
Uncoated carbide: Shorter lifespan (~20–30% less than coated).
TiAlN, TiCN, or Diamond coatings: Extend life significantly (50–300% in some cases).
Coolant/Lubrication:
Dry cutting: Risk of overheating (except in aluminum).
Flood coolant/mist: Extends life in steels & exotics.
Air blast/chip evacuation: Helps prevent recutting chips (abrasive wear).
Tool Geometry & Flute Count:
More flutes = higher feed but less chip clearance (risk of clogging in gummy materials).
Corner radius (bullnose) tools last longer than sharp corners.
Machine Rigidity & Vibration:
Poor setups or deflection cause chipping and premature failure.
Replace or resharpen when you observe:
Poor surface finish (chatter, burrs).
Increased cutting forces/vibration.
Chipping or dull cutting edges (visible under magnification).
Discoloration (overheating).
Optimize speeds/feeds using manufacturer guidelines.
Use toolpath strategies (e.g., trochoidal milling) to reduce heat.
Avoid dwell times that cause work-hardening.
Keep tools sharp—resharpen before excessive wear.