| Aluminum and Aluminum Alloys | Solid carbide end mill or high-feed face mill with polished flutes | Slotting, pocketing, profiling, and finishing | 35°–45°
Higher helix for smoother cutting | Positive rake, typically +10° to +15°; relief angle about 8°–12° | 2 or 3 flutes; sharp, polished cutting edges; large flute volume | Use compressed air, minimum-quantity lubrication, or flood coolant where appropriate | Positive and polished geometry reduces built-up edge and promotes fast chip removal |
| Low-Carbon and Mild Steel | General-purpose carbide end mill or indexable shoulder mill | Roughing, shoulder milling, pocketing, and general profiling | 30°–40°
Variable helix can reduce vibration | Neutral to moderately positive rake, approximately 0° to +8°; relief about 8°–12° | 4 or 5 flutes; variable pitch preferred for unstable setups | Flood coolant or directed air; maintain a clear chip path in deep pockets | Balanced geometry provides tool strength while maintaining productive metal removal |
| Alloy and Precipitation-Hardening Stainless Steel | Variable-helix carbide end mill with a reinforced core | Slotting, contouring, adaptive roughing, and finishing | 35°–45°
Variable pitch helps control chatter | Positive rake, approximately +5° to +10°; relief about 8°–12° | 4 or 5 flutes; strong edge preparation; avoid excessively sharp fragile edges | High-pressure coolant or a strong directed coolant stream is useful for chip evacuation | Controlled positive geometry limits work hardening and reduces heat concentration |
| Titanium and Titanium Alloys | Variable-helix carbide end mill or specialized high-feed cutter | Adaptive roughing, side milling, and shallow radial finishing cuts | 30°–45°
Variable pitch reduces harmonic vibration | Moderately positive rake, approximately +5° to +10°; relief about 8°–12° | 3 or 4 flutes; strong core and edge reinforcement; avoid rubbing | High-pressure coolant is commonly preferred; use short tool overhangs | Rigid geometry and efficient cooling help control heat, deflection, and work hardening |
| Gray and Ductile Cast Iron | Carbide face mill or end mill with chamfered edges | Face milling, roughing, and step-down pocketing | 20°–35°
Lower helix improves edge support | Neutral or slightly negative rake; relief generally about 5°–8° | Strong chamfered edge; 4 or more flutes for face milling | Dry machining or compressed air is often suitable; avoid trapping abrasive dust | Reinforced edges resist the abrasive action and interrupted cutting common in cast iron |
| Tool Steel and Hardened Steel up to Approximately 55 HRC | Fine-grain carbide, coated carbide, or ceramic-capable cutter selected for hardness | Hard roughing, profiling, and semi-finishing | 20°–35°
Lower or variable helix for rigidity | Neutral to slightly negative rake; relief about 7°–10° | 4 or 5 flutes; strong edge preparation and short cutting length | Air blast or controlled coolant; use stable clamping and minimize tool deflection | Robust geometry protects the edge against impact, heat, and high cutting forces |
| Hardened Steel Above Approximately 55 HRC | Dedicated hard-milling carbide cutter with a reinforced edge | Finishing, 3D profiling, and die-and-mold machining | 10°–30°
Ball-nose tools often use variable geometry | Neutral or slightly negative rake; relief about 7°–10% | Fine edge preparation; ball-nose or bull-nose form for complex surfaces | Air blast is commonly used; avoid thermal shock unless the cutter is designed for wet cutting | Strong edges and controlled engagement support predictable hard-milling performance |
| Copper, Brass, and Bronze | Sharp polished carbide end mill or non-ferrous-specific cutter | Slotting, profiling, drilling-milling, and finishing | 30°–45°
Higher helix improves shearing action | Positive rake, approximately +10° to +20°; relief about 10°–15° | 2 or 3 flutes; polished flutes and a sharp edge | Air blast or light lubrication; ensure chips do not recut in narrow slots | Sharp, polished geometry minimizes smearing, burr formation, and material adhesion |
| Engineering Plastics | Polished high-helix carbide cutter, often with an upcut or compression profile | Through-slotting, contouring, trimming, and pocketing | 30°–45°
Choose a compression design for laminated sheets | Positive rake, approximately +10° to +20°; relief about 10°–15° | 1 or 2 flutes; large gullets and very sharp polished edges | Compressed air is preferred; use coolant only when compatible with the polymer | Large chip spaces and low-friction surfaces reduce melting, recutting, and burrs |
| Carbon-Fiber and Glass-Fiber Composites | Diamond-coated carbide cutter, compression cutter, or dedicated composite router | Trimming, edge profiling, pocketing, and laminate machining | 10°–30°
Geometry depends on laminate direction and delamination risk | Controlled positive or neutral rake; relief commonly about 10°–15° | Compression, burr-style, or diamond-abrasive edge; short overhang preferred | High-volume vacuum extraction and air cooling; control airborne dust | Geometry is selected to limit fiber pullout, delamination, and abrasive edge wear |
| Nickel-Based Heat-Resistant Alloys | Rigid carbide cutter with heat-resistant coating and strong edge preparation | Low radial-engagement roughing and controlled finishing | 30°–45°
Variable helix helps manage vibration | Moderately positive rake, approximately +3° to +8°; relief about 8°–12° | 4 or 5 flutes; reinforced edges and high tool stiffness | High-pressure coolant and strong chip evacuation are important | Rigid, heat-resistant geometry limits notch wear, work hardening, and thermal damage |
| Austenitic Stainless Steel in Thin Sections | Variable-pitch carbide end mill with a sharp but reinforced edge | Thin-wall profiling, finishing, and light slotting | 35°–45°
Variable pitch helps suppress vibration | Positive rake, approximately +5° to +10°; relief about 10°–12° | 4 or 5 flutes; reduced cutting length and strong core | Directed coolant or high-pressure coolant; avoid dwell and rubbing | Positive shearing action and low radial force help protect thin walls from deflection |
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