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HSS or Carbide: Which Milling Cutter is Best for Your Application
When it comes to milling, one of the most important decisions you’ll make is whether to use HSS cutters or Carbide cutters. Each tool material offers unique advantages, from toughness and affordability to speed and durability, and the right choice depends on your machine, the material you’re cutting, and your production goals.
In this guide, we’ll break down the key differences between HSS vs Carbide milling cutters, explore their pros and cons, and help you determine which option delivers the best performance and value for your application.
Here’s what you’ll see:
An HSS cutter (High-Speed Steel cutter) is a milling tool made from alloyed tool steel designed to withstand higher cutting speeds than traditional carbon steels. HSS has been used in machining for decades thanks to its toughness and versatility.
While not as hard or long-lasting as carbide cutters, HSS milling cutters remain a popular choice for many applications due to their balance of performance and affordability.
HSS cutters are widely used in:
Manual machines where rigidity may be limited.
General-purpose milling of softer metals such as aluminium, brass, and mild steel.
Applications where shock resistance and toughness are more important than extreme hardness.
Workshops where tools are regularly resharpened and reused to keep costs low.
Because they are more forgiving than carbide, HSS cutters are a reliable option for less experienced machinists and smaller-scale operations.
HSS milling cutters typically have a hardness rating of around 62–64 HRC (Rockwell Hardness C). While this is significantly lower than carbide (which can exceed 80–90 HRC), the toughness of HSS means it can absorb more shock and is less likely to chip or fracture under unstable conditions.
A type of high-speed steel alloy that contains 8% cobalt. It is a tool steel that has excellent hardness, wear resistance, and heat resistance properties. The addition of cobalt makes the tool more durable and capable of withstanding higher temperatures during cutting operations.
A type of high-speed steel alloy that contains 5% cobalt. This type of HSS is known for its excellent combination of hardness, toughness, and wear resistance. Having 5% cobalt makes the tool more robust.
The lowest grade of high-speed steel without any cobalt content. Not commonly seen in metalworking anymore due to newer substrates being developed that are higher performing.
Read More: Types Of Milling Cutters: Expert Guide to CNC Cutting Tools
Excellent toughness and resistance to chipping.
Lower initial cost compared to carbide cutters.
Easy to regrind and re-sharpen, extending tool life economically.
Versatile for softer materials and a wide range of applications.
Lower hardness and wear resistance than carbide.
Shorter tool life, especially when machining harder alloys.
Limited cutting speeds, which generate more heat at higher RPMs.
Less suitable for high-production CNC machining.
A carbide milling cutter is a cutting tool made from tungsten carbide particles bonded with cobalt. Carbide is significantly harder and more heat-resistant than High-Speed Steel (HSS), which makes these tools ideal for high-speed machining, precision applications, and demanding materials.
Carbide cutters are available in both solid carbide and carbide insert designs. Solid carbide tools offer extreme hardness and long tool life, while cutters with replaceable carbide inserts provide versatility and cost savings for larger tools.
Milling cutters with carbide inserts are widely used in industrial machining where durability and performance are critical. They are commonly used for:
High-speed CNC machining of steels, stainless steels, and hardened alloys.
Heavy-duty milling operations in automotive, aerospace, and die & mould industries.
Applications requiring consistent precision and superior surface finish.
Situations where inserts can be replaced instead of regrinding a solid tool, reducing downtime and cost.
Carbide inserts are especially valuable in production environments where efficiency and tool life are top priorities.
The different types of carbide include:
This refers to carbide materials that have relatively larger carbide grains, typically in the range of 0.2 to 2 micrometers.
The larger grain size provides increased toughness and impact resistance, making micrograin carbide suitable for applications that involve interrupted cutting, difficult-to-machine materials, or heavy machining operations.
This refers to carbide materials with smaller carbide grain sizes compared to micrograin carbide. The grain size typically ranges from 0.1 to 0.5 micrometers.
The smaller grain size provides improved hardness and wear resistance, making ultrafine carbide suitable for applications that require high precision, fine surface finishes, and extended tool life.
This takes the concept of grain size reduction even further, with grain sizes typically in the range of a few nanometers (less than 100 nanometers). The extremely small grain size enhances the material's hardness, wear resistance, and overall strength.
Nanograin carbide is used in applications that demand exceptional performance, such as high-speed machining, fine finishing, and cutting of very hard materials.
Extreme hardness and wear resistance.
Maintain cutting edge at very high temperatures.
Enable faster cutting speeds and higher feeds.
Longer tool life compared to HSS cutters.
Excellent surface finish on tough materials.
More brittle than HSS, prone to chipping under vibration or interrupted cuts.
Higher upfront cost.
Require rigid setups to perform effectively.
Less suitable for manual machines or unstable machining conditions.
|
Feature |
HSS Cutters |
Carbide Cutters |
|
Hardness |
~62–64 HRC |
~80–90 HRC |
|
Toughness |
High (resists chipping, good for unstable setups) |
Moderate (can chip if vibration occurs) |
|
Heat Resistance |
Limited – loses hardness at high temperatures |
Excellent – retains hardness at elevated temps |
|
Cutting Speed |
Low to medium |
High (suitable for CNC and production machining) |
|
Tool Life |
Shorter, needs frequent regrinding |
Longer, holds sharp edge much longer |
|
Cost |
Lower upfront, economical |
Higher upfront, cost-effective long-term |
|
Best Applications |
Softer materials (aluminium, brass, mild steel), manual machining, lower budgets |
Hard alloys (stainless steel, titanium, cast iron), CNC machining, high-volume production |
|
Maintenance |
Easy to regrind and reuse |
Inserts can be replaced, solid carbide less serviceable |
Choosing between HSS cutters and Carbide cutters depends on the material you’re machining, the type of machine you’re using, and your production goals. Each has its place in the workshop.
Manual machining: Ideal for older or less rigid machines where shock resistance is important.
Soft to medium materials: Works well on aluminium, brass, copper, and mild steels.
Low-volume or budget-sensitive jobs: Lower purchase cost and the ability to regrind make HSS more economical.
Beginner-friendly setups: Forgiving of vibration and imperfect feeds, reducing the risk of tool failure.
CNC machining: Excellent for rigid, high-speed machines designed to maximise tool performance.
Hard materials: The best choice for stainless steel, titanium, hardened alloys, and cast iron.
High-volume production: Faster cutting speeds and longer tool life reduce downtime and improve efficiency.
Precision work: Offers tighter tolerances and superior surface finishes.
Powder metal is another substrate that is commonly used in various milling applications. This can include general milling, profiling, slotting and more.
Powder metal is often more cost-effective than solid carbide cutters while still delivering excellent performance. With high wear resistance, long tool life is achieved.
Powder Metal Milling Cutters can withstand higher cutting speeds, making them suitable for high-speed machining applications.
Powder metal also offers similar performance to carbide with the toughness of HSS. Therefore, it is ideal to use it when HSS wears too fast and where carbide is too brittle.
It depends on the application. HSS cutters are tougher, more affordable, and best for softer materials or manual machining. Carbide cutters are harder, faster, and longer lasting, making them the better choice for CNC machining and hard alloys.
Yes, if you’re machining hard materials, running high-volume jobs, or using CNC machines. Although Carbide tools cost more upfront, their longer tool life and higher productivity often make them more cost-effective in the long run.
HSS cutters can machine stainless steel, but they will wear out quickly. For consistent performance and longer tool life, Carbide cutters are the recommended choice for stainless steel and other hard alloys.
Tool life depends on material, cutting speed, and setup. In general, Carbide cutters last significantly longer than HSS cutters, often several times longer, especially when machining tough materials at high speeds.
HSS cutters can be easily re-ground multiple times, making them cost-effective for small workshops. Carbide cutters can also be re-sharpened, but the process is more complex and may require specialist equipment.
HSS cutters: typically, around 62–64 HRC. Carbide cutters: can exceed 80–90 HRC, offering much higher wear resistance.
Both HSS and Carbide cutters can machine aluminium effectively. For general use and cost savings, HSS works well. For high-speed CNC machining, Carbide cutters are preferred due to their ability to run at faster speeds without losing edge sharpness.
At Cutwel, we supply one of the UK’s largest selections of milling cutters, designed to suit every application and budget.
Whether you need the toughness of HSS cutters for manual machining or the speed and durability of carbide cutters for CNC production, we’ve got you covered.
Our range includes:
HSS Milling Cutters: reliable, affordable, and easy to regrind.
Solid Carbide Milling Cutters: superior hardness and tool life for demanding jobs.
Carbide Insert Cutters: versatile solutions with replaceable inserts for cost efficiency.
Specialist Milling Tools: ball nose, roughing, slot drills, and more for precision work.
Partnering with trusted suppliers like Cutwel ensures access to a full range of milling cutters, technical support with expert advice, and after-sales support - helping businesses stay competitive and compliant.
