Contents

• Introduction to High Feed Milling
• A Brief History of High Feed Milling
• What is High Feed Milling?
• Key Benefits of High Feed Milling
• Machining Strategies for High Feed Milling
• Future Trends in High Feed Milling
• When Should You Use High Feed Milling?
• Best Selling high feed systems
• Summary of high feed systems

Introduction to High Feed Milling

In the fast-paced world of CNC machining, time is money—and when you're cutting hard metals, deep cavities, or working on tight deadlines, you need more than just conventional techniques. That's where High Feed Milling (HFM) comes into play. This advanced roughing method allows machinists to remove material faster, smarter, and with less tool wear.

In this post, we’ll explore what exactly high feed milling is, how it comes about, and how it can boost your productivity. 

A Brief History of High Feed Milling

High Feed Milling first emerged in the 1990s, driven by the need to improve material removal rates (MRR) during roughing operations—especially in aerospace, automotive, and mold and die sectors.

The technology matured alongside:

•    The development of stronger insert-style milling cutters

•    Rigid CNC machines capable of handling dynamic loads

•    Advances in toolholder technology and spindle speeds

Tool manufacturers began designing cutters with very small lead angles (typically around 10°–20°), which redirected cutting forces axially into the spindle rather than radially into the tool. This simple change made it possible to use much higher feed rates without overloading the tool or machine.

What is High Feed Milling?

High Feed Milling is a roughing strategy that uses tools with a small entering angle, allowing for:

•    Shallow depth of cut (DOC)

•    Very high feed per tooth (fz)

•    Low radial engagement

This means the tool skims through the material with less resistance, enabling higher feed rates while still maintaining chip thinning—perfect for productivity and tool longevity.

Key Benefits of High Feed Milling

1. Faster Material Removal

•    High feed per tooth means you can take shallow cuts at blistering speeds.
•    Great for bulk roughing operations and deep cavities.

2. Longer Tool Life

•    Lower radial forces reduce stress and vibration on the tool and machine.
•    Especially useful in hard-to-machine materials like Inconel, titanium, and hardened steels.

3. More Efficient Machining

•    Allows aggressive feed rates on lower-power machines.
•    Enables step-down strategies in deep pockets without deflection or chatter.

4. Lower Costs Per Part

•    Fewer tool changes.
•    Shorter cycle times.
•    Less spindle wear and lower risk of tool breakage.

Machining Strategies for High Feed Milling

Here’s how to implement HFM successfully in your shop:

1. Use Dedicated High Feed Tools

•    These typically feature a small lead angle and strong positive geometry.
•    Example: 10°–20° lead angle inserts in multi-tooth face mills or button cutters.

2. Optimise CAM Toolpaths

•    Use constant Z-step down for deep pockets.
•    Combine with adaptive or trochoidal milling for curved geometries.

3. Reduce Axial Depth, Increase Feed

•    Keep DOC shallow (0.5–1.5 mm depending on material).
•    Use high feed per tooth (up to 1.5 mm/tooth in some cases).

4. Leverage High-Performance Holders

•    Use rigid, balanced holders (like shrink-fit or hydraulic chucks).
•    Avoid long overhangs unless using vibration-damped tooling.

5. Monitor Chip Thickness

•    HFM creates very thin chips; make sure chips are thick enough to carry heat away.
•    Adjust feed rates to maintain minimum chip thickness.

Future Trends in High Feed Milling

1. Smart Tooling Integration

•    Sensors embedded in cutters for real-time load and temperature monitoring.

2. AI-Powered CAM Automation

•    CAM software that dynamically adjusts feed rates and engagement based on tool wear and part geometry.

3. Hybrid Roughing Approaches

•    Combining high feed milling with high-efficiency machining (HEM) for parts requiring both speed and fine finishes.

4. Tool Innovations

•    Insert coatings and edge preps tailored specifically for HFM in superalloys.
•    Lighter tool bodies with better chip evacuation and coolant routing.

When Should You Use High Feed Milling?

Use HFM when:

•    You’re roughing hard metals or deep pockets

•    Tool wear is a recurring issue in conventional roughing

•    You're working on low-horsepower machines but still want aggressive metal removal

•    Surface finish isn’t a priority (HFM is for roughing, not finishing)

Pro Tip: For finishing operations, switch to a conventional finishing tool after HFM roughing to save time and tool life.

Best Selling high feed systems

•    Korloy HRM double – for larger parts

•    YG-1 HF4 – for medium sized parts

•    Korloy HFM – for small or high precision parts

Summary of high feed systems

High Feed Milling is one of the smartest strategies you can add to your machining playbook. It’s not just about speed—it’s about reducing tool wear, cutting cycle time, and extending machine life while pushing the limits of what your shop can handle. As machines get smarter, cutters get tougher, and software gets more intelligent, high feed milling will only continue to grow in value and versatility.

Have you tried high feed milling yet?
Please feel free to contact our expert in-house technical support team who can provide even more knowledge and expertise on 01924 869 615 or email sales@cutwel.net.