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Material-Based End Mill Selection

Steel & Pre-Hardened Steel Milling

Choose an end mill for steel using the steel class and condition, operation, feature, tool diameter, engagement and machine setup. Compare MSU GP, GPP and HPX families for non-alloy, low-alloy and high-alloy or tool steels.

For pre-hardened steel, include the exact grade and measured hardness. GP, GPP and HPX families are listed for material below 55 HRC. For higher hardness, compare Hardened Steel Milling using the measured hardness, grade and operation.

Send the steel grade, hardness, operation, dimensions and machine conditions for an application-specific review.

Request a Steel Milling Review

Define Your Requirement

Provide the steel designation or specification, condition and measured hardness. These details help select GP, GPP or HPX tools or identify a hardened-steel requirement.

  • Operation Slotting, shoulder milling, side milling, profiling, pocketing, contouring or finishing.
  • Feature Flat floor, wall, radius, three-dimensional contour or another controlled geometry.
  • Tool requirement Square, ball-nose or corner-radius end, diameter, flute length, overall length and reach.
  • Engagement Axial depth, radial width, full slot or partial engagement.
  • Setup Machine, spindle interface, holder, overhang, workholding and available coolant or air.
  • Commercial input Required quantity, destination and target date.
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Use these details to shortlist a tool and select starting speed, feed and engagement for the application.

Compare the steel grade and hardness with the GP, GPP and HPX catalog options.

Compare Steel Milling Families

Selection Factors

Compare the GP, GPP and HPX starting values only after the steel category, condition, hardness, operation, engagement and cutter diameter are known.

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GP / GPP Values HPX Values

GP and GPP Starting Values

The following GP/GPP values are starting points for profile milling (finishing), Ap = 0.2 D and Ae = 0.3 D. Cutter diameters are 2, 4, 6, 8, 10, 12, 14, 16 and 20 mm. Each fz sequence follows that diameter order and is stated in mm/tooth.

Steel category Subtype Condition HB Vc (m/min) fz by listed diameter (mm/tooth)
Non-alloy steel C <= 0.25% Normalized 125 140-240 0.018, 0.047, 0.076, 0.104, 0.135, 0.149, 0.162, 0.176, 0.189
Non-alloy steel 0.25% < C <= 0.55% Normalized 190 230-330 0.020, 0.052, 0.084, 0.116, 0.150, 0.165, 0.180, 0.195, 0.210
Non-alloy steel 0.25% < C <= 0.55% Quenched and tempered 210 230-330 0.020, 0.052, 0.084, 0.116, 0.150, 0.165, 0.180, 0.195, 0.210
Non-alloy steel C > 0.55% Normalized 190 190-310 0.019, 0.049, 0.080, 0.110, 0.143, 0.157, 0.171, 0.185, 0.200
Non-alloy steel C > 0.55% Quenched and tempered 300 140-240 0.018, 0.047, 0.076, 0.104, 0.135, 0.149, 0.162, 0.176, 0.189
Non-alloy steel Free-cutting steel Quenched and tempered 220 190-310 0.019, 0.049, 0.080, 0.110, 0.143, 0.157, 0.171, 0.185, 0.200
Low-alloy steel Not specified Annealed 175 190-310 0.019, 0.049, 0.080, 0.110, 0.143, 0.157, 0.171, 0.185, 0.200
Low-alloy steel Not specified Normalized 300 140-240 0.018, 0.047, 0.076, 0.104, 0.135, 0.149, 0.162, 0.176, 0.189
Low-alloy steel Not specified Quenched and tempered 380 110-210 0.017, 0.045, 0.072, 0.100, 0.129, 0.142, 0.155, 0.168, 0.181
Low-alloy steel Not specified Quenched and tempered 430 90-190 0.016, 0.043, 0.069, 0.095, 0.123, 0.135, 0.148, 0.160, 0.172
High-alloy steel / high-alloy tool steel Not specified Annealed 200 140-240 0.018, 0.047, 0.076, 0.104, 0.135, 0.149, 0.162, 0.176, 0.189
High-alloy steel / high-alloy tool steel Not specified Quenched and tempered 300 140-240 0.018, 0.047, 0.076, 0.104, 0.135, 0.149, 0.162, 0.176, 0.189
High-alloy steel / high-alloy tool steel Not specified Quenched and tempered 400 110-210 0.017, 0.045, 0.072, 0.100, 0.129, 0.142, 0.155, 0.168, 0.181

HPX Starting Values

The following HPX values are starting points for shoulder milling (finishing), Ap = 1.5 D and Ae = 0.03 D. Cutter diameters are 4, 6, 8, 10, 12, 14, 16, 18 and 20 mm. Each fz sequence follows that diameter order and is stated in mm/tooth.

Steel category Subtype Condition HB Vc (m/min) fz by listed diameter (mm/tooth)
Non-alloy steel C <= 0.25% Normalized 125 160-280 0.063, 0.090, 0.117, 0.144, 0.171, 0.198, 0.234, 0.261, 0.288
Non-alloy steel 0.25% < C <= 0.55% Normalized 190 220-340 0.070, 0.100, 0.130, 0.160, 0.190, 0.220, 0.260, 0.290, 0.320
Non-alloy steel 0.25% < C <= 0.55% Quenched and tempered 210 220-340 0.070, 0.100, 0.130, 0.160, 0.190, 0.220, 0.260, 0.290, 0.320
Non-alloy steel C > 0.55% Normalized 190 200-320 0.067, 0.095, 0.124, 0.152, 0.181, 0.209, 0.247, 0.276, 0.304
Non-alloy steel C > 0.55% Quenched and tempered 300 150-270 0.063, 0.090, 0.117, 0.144, 0.171, 0.198, 0.234, 0.261, 0.288
Non-alloy steel Free-cutting steel Quenched and tempered 220 200-320 0.067, 0.095, 0.124, 0.152, 0.181, 0.209, 0.247, 0.276, 0.304
Low-alloy steel Not specified Annealed 175 200-320 0.067, 0.095, 0.124, 0.152, 0.181, 0.209, 0.247, 0.276, 0.304
Low-alloy steel Not specified Normalized 300 150-270 0.063, 0.090, 0.117, 0.144, 0.171, 0.198, 0.234, 0.261, 0.288
Low-alloy steel Not specified Quenched and tempered 380 120-240 0.060, 0.086, 0.112, 0.138, 0.163, 0.189, 0.224, 0.249, 0.275
Low-alloy steel Not specified Quenched and tempered 430 100-210 0.057, 0.082, 0.107, 0.131, 0.156, 0.180, 0.213, 0.238, 0.262
High-alloy steel / high-alloy tool steel Not specified Annealed 200 150-270 0.063, 0.090, 0.117, 0.144, 0.171, 0.198, 0.234, 0.261, 0.288
High-alloy steel / high-alloy tool steel Not specified Quenched and tempered 300 150-270 0.063, 0.090, 0.117, 0.144, 0.171, 0.198, 0.234, 0.261, 0.288
High-alloy steel / high-alloy tool steel Not specified Quenched and tempered 400 120-240 0.060, 0.086, 0.112, 0.138, 0.163, 0.189, 0.224, 0.249, 0.275

Verify the tool code, end form, steel grade, hardness, machine, holder, overhang, workholding, coolant and engagement before applying these starting values. Begin conservatively and validate the result in your setup. See the End Mill Selection Guide, End Mill Coating Guide and End Mill Flute Count Guide for related selection factors.

Submit the exact steel and setup information before a starting value is applied to a specific tool.

Send Steel Milling Conditions

Catalog and Application Requirements

Compare the GP, GPP and HPX catalog families and starting tables using the stated steel categories, conditions and machining operations.

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Material and machining requirements

The catalog lists GP, GPP and HPX families for material below 55 HRC. Match the product code to the steel grade, operation and setup. Assess tool life, cycle time, stock removal, finish and accuracy under the actual cutting conditions when comparing tools.

Verification route

MSU manufactures these carbide end mills. See Factory for manufacturing information and Quality Control for inspection requirements. Check family codes and dimensions in the current Downloads before requesting a quotation.

Use the current catalog to verify the product code and keep every material and operating condition attached to the selection.

View End Mill Catalogs

Standard or Custom Options

Compare standard catalog geometry and dimensions with your application, or submit the required changes for custom engineering review.

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Standard catalog route

Use a standard catalog route when the required end form, diameter, flute length, reach and other dimensions match a current product code. Confirm the complete code and quantity rather than ordering from the family name alone.

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Custom engineering route

Use Custom Cutting Tools when the required diameter, length, reach, flute count, end geometry, corner radius, chamfer, helix, substrate or coating needs engineering review. A submitted requirement can be reviewed for feasibility, but not every combination is guaranteed to be manufacturable.

MOQ is normally 5-10 pieces and is confirmed by product and quotation. Samples are chargeable, and sample freight is paid by the customer. Completion of the whole order is guaranteed within 25–30 days from order placement. Payment can be discussed by T/T with deposit and balance stages defined in the quotation or order. EXW, FOB, CIF and DDP can be discussed subject to the destination and actual feasibility. See Ordering and Delivery for the shared commercial process.

Move to the custom review route when the standard catalog dimensions or geometry do not match the application.

Review Custom Cutting Tools

Steel Milling Questions

Which steel materials can I submit for tool selection?

Compare GP, GPP and HPX for non-alloy, low-alloy and high-alloy or tool-steel applications. Submit the exact grade, condition and hardness for selection.

When should I use the Hardened Steel Milling page?

Use Hardened Steel Milling for material above the GP/GPP/HPX catalog range or a hardened-steel machining requirement. Include the exact grade and measured hardness.

Does below 55 HRC mean every GP, GPP or HPX tool is guaranteed at that hardness?

The catalog lists these families for material below 55 HRC. Select the exact tool using the material grade, operation and setup, then validate its performance under those conditions.

Can I apply the listed parameters to any end form?

The values are series-level starting points under the stated conditions. Select and adjust them for the exact square, ball-nose or corner-radius product and machining setup.

How do I choose between square, ball-nose and corner-radius tools?

Match the end form to the workpiece feature and toolpath. Submit the drawing or feature description when the required geometry is not clear.

Can MSU review a current competitor tool or failed application?

Yes. Send the complete current-tool code, photographs, failure mode, material, program conditions and required result. MSU can use these details to assess a possible replacement or application change.

Can I request a custom end mill for steel?

Yes. Submit the drawing or complete geometry, material, hardness, operation, quantity and acceptance requirements for feasibility review.