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Reference Chart
Face Mill Feeds & Speeds Chart
Optimized data for 45° and 90° indexable face mills. Learn how lead angle affects chip load and feed rates.
Chip Thinning Calculator
Using a 45° face mill or high-feed cutter? You MUST increase your programmed feed rate to get the correct chip thickness.
Surface Speed (SFM) by Material
Typical starting parameters for 2" - 4" diameter face mills with coated carbide inserts.
| Material Group | SFM Range (Carbide) | Chip Load (IPT) | Notes |
|---|---|---|---|
| Aluminum (6061/7075) | 1500 - 4000 | 0.005" - 0.020" | Run WET or MQL. High polish inserts. |
| Low Carbon Steel (1018) | 600 - 1000 | 0.004" - 0.012" | Run DRY. Air blast. |
| Alloy Steel (4140) | 400 - 700 | 0.003" - 0.008" | Run DRY. Watch for thermal cracking. |
| Stainless (304/316) | 300 - 550 | 0.003" - 0.006" | Run DRY (modern grades) or WET. Don't dwell. |
| Cast Iron (Grey) | 500 - 900 | 0.005" - 0.015" | Run DRY. Abrasive dust. |
| Titanium (6Al4V) | 120 - 200 | 0.002" - 0.005" | Run WET. High pressure coolant. |
Lead Angle & Chip Thinning
If you use a 45° face mill (common for smooth cutting), the chip is physically thinner than your programmed feed rate. You must increase feed rate to maintain the proper chip thickness.
90°
Shoulder Mill
Square Shoulder
Factor: 1.00x
Feed = Chip Load
Most Common
45°
Face Mill
Chamfer Edge
Factor: 1.41x
Feed = Chip Load × 1.41
Rd
Button / High Feed
Round Insert
Factor: Variable
Depends on Depth of Cut
Face Milling Pro Tips
- Roll In: Always arc into the cut. Converting straight-line entry to an arc prevents insert chipping.
- Engagement: Ideally keep 60-70% of the cutter diameter engaged in the material.
- Exit: Avoid exiting the part where the insert is thickest. Adjust path to ensure thin chip formation on exit.
- Climb Mill: Almost always climb mill (down milling) for face milling to direct forces into the table.