w w w .

m i l l

Cost cutting and time saving tools for profile and cavity milling in the auto, aircraft,
die and mold industries, and in general manufacturing.
• Insert Style Ball Nose Roughing and Finishing Tools
• Flat Bottom, Back Draft and Toroid Bull Nose Tools
• SuperFinisher Inserts
• New Long Reach Solid Carbide Shanks
Millstar tools are designed for conventional profile machining, and for high speed and hard milling
with modern machine tools and methods. Tool holders and inserts are available in inch
and metric sizes. This issue of the Millstar catalog also features special and
new inserts: special left hand tools for “mirror image” milling, a series of
aggressively positive inserts for cutting aluminum and non-ferrous
materials, a Toroid bull nose series and a SuperFinisher series.

THE TOOL HOLDERS

Now Available
High performance and ultra-
precise solid carbide end mills
designed specifically for High
Speed, High Velocity and Hard
Steel Milling. See pages 20, 21,
24 & 25.
Millstar is proud to offer the largest machining speeds and increased
selection of roughing and finishing ball productivity. Millstar tools are designed
nose, back draft, flat bottom and toroid to keep pace.
milling cutters available from one The Millstar product line is
source. Cylindrical and tapered manufactured in the USA under ISO
toolholders (to 15 inch length) include 9001 specifications, and all tools are
the longest reach profiling tools available fully traceable. Nearly six decades of
as standard catalog items. Tool holders
are inherently balanced for high spindle
cutting tool design and manufacturing
for automotive, aerospace and
speeds. Machine with confidence at the many other industries, as well
increased speeds and velocities dictated as special design capabilities
by modern high velocity machining. using 3-D CAD allow us
Super intelligent machine controls with to respond quickly
high speed data transfer, rapid advances to requests for
in cutting edge materials and coating special designs.
technologies enable ever faster
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Profile Milling Tools
Millstar Profile Milling Tools represent the latest in profile and contour milling technology, providing you with the
competitive edge of shorter machining and lead times, and the competitive advantages of higher machining accuracy
and true contouring results.
Better surface finishes
Run and feed faster
Increased tool life
Mill with accuracy & consistency
Two-flute efficient, balanced milling action
THE INSERTS
• Millstar inserts are fully ground
precision inserts for better chip control,
faster metal removal and higher
surface accuracies. They are far more
accurate than pressed and O.D.
sharpened inserts. Millstar insert radius
and seat are accurate to +/- 0.00025"
(+/- 0.0065 mm) of nominal radius and
cut exactly as programmed. This
unparalleled accuracy also eliminates
redundant Z-axis pick ups and assures
accurate blending.
• Positive ground chipbreaker or strong
negative cutting edge designs
guarantee outstanding cutting
performance in a wide variety of
ferrous and non-ferrous materials.
• A choice of state-of-the-art insert
grades, designs and tool coatings allow
for optimum speed and feed rates in
wet and dry machining. Reduced
machining times by 25% to 60% are
not uncommon.
Warren MI 48092 USA
o m TEL (586)573-9450
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= Reduced finishing work
= Reduced machining time
= Reduced tool changes and cost
= Reduced manual rework
= Greatly increased metal removal productivity
Rock Solid
Insert Clamping
Cutting insert clamping is highly
accurate and rigid. Unique V-pocket
design gives a truly positive seat for
the insert and will not allow insert
movement when milling with a side
thrust. “Sandwiched” insert
clamping with single locking screw
is unsurpassed for rigidity. The
advanced design of Millstar inserts
eliminates heat-seizing of locking screws or insert movement due to costly
locating screws or pins of less advanced design. Positive V-pocket seating
eliminates mismatch when changing to fresh inserts. It also eliminates the need
to program new length or diameter offsets.
• Economical one-piece inserts with two and for a wider range of applications
cutting edges are cost-effective for compared to conventional ball
contour milling. True radius geometry nose tools.
is fully CNC-ground for higher • Select from a variety of flat bottom,
machining accuracy and greatly back draft and toroid inserts for steep
reduced manual finishing and or straight wall milling with long
polishing time. extensions on hard to reach cores,
• Choose from side-cutting ball nose cavities or fillets. Milling with small
inserts with 180 degree nose radius, radii prevents deflection and results in
and popular ball nose inserts with a superior finishes and contour
cutting edge covering 230 degrees for accuracies. Available with or without
steep wall up-and-down ramping, chipbreaker and coating in a variety
profiling, contour milling and blending, of corner radii and sizes.
3
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LONG REACH SOLID CARBIDE SHANKS

D2

D D1

L1

L2

Millstar’s long solid carbide tool shank cutters provide the user with deep milling
solutions for up to ten times diameter in reach. MILLSTAR’s Carbide Tool Shanks
provide many user benefits:
• Increased stiffness – for more aggressive metal removal and long reach, deep milling.
• Large cutting insert choice – the variety of available cutting geometry, tool coatings, and insert
shapes and sizes assures best milling results at lowest machining cost per part.
• Minimized deflection – to machine closer to net shape and tight tolerance.
• Vibration reducing – for smoother surface finish, improved tool life, longer
spindle life.
• Minimized cutter run out – improved milling results in soft to fully hardened (to 65
HRc) materials.
• Smaller shank to cutter diameter – several sizes have full-length side clearance to
machine straight walls.
• Safe high speed milling – highest tool stiffness and least deflection when
compared with steel and heavy metal tool shanks result in process
reliability and highest safety for operator and machine.
• Shank diameters (h6) – all tool shanks are heat shrink-fit tool adapter
compatible.

Tool Size Ø Insert Overall Neck Shank Ø Neck D2 Nose Screw/

Ordering Nr. D Style Length L2 Length L1/taper D1 (h6) mm Taper wrench
CBTAV 06-75-12* 6 75 35 / 1.5˚ 12 5.7 3˚ (1.5˚/side) MS 06N / T7
CBTAV 06-150-12* 6 155 30 / 6˚ 12 5.7 6˚ (3˚/side) MS 06N / T7
CBTAV 06-150-12 LT* 6 155 70 / 6˚ 12 5.7 6˚ (3˚/side) MS 06N / T7
CBCYV 06-115-12*** 6 115 30 cyl. + 45 / 1.5˚ 12 5.7 2˚ (1˚/side) MS 06N / T7
CBTAV 08-80-12* 8 80 40 / 1.5˚ 12 7.5 3˚ (1.5˚/side) MS 08N / T7
CBTAV 08-150-12* 8 155 30 / 6˚ 12 7.5 6˚ (3˚/side) MS 08N / T7
CBCYV 08-100-12*** 8 100 30 cyl. + 30 / 1.5˚ 12 7.5 2˚ (1˚/side) MS 08N / T7
CBCY 10-150-10 10 150 32 10 9.0 – MS 10 / T15
CBTA 10-150-12 10 165 30 / 6˚ 12 9.0 6˚ (3˚/side) MS 10 / T15
CBSFTA 10-150-12 10 165 30 / 6˚ 12 9.0 6˚ (3˚/side) MS 10 / T15
CBSFCY 12-150-12 12 165 52 12 10.8 – MS 12 / T20
CBCYF 12-150-12 12 165 52 12 10.8 – MS 12 / T20
CBSFCY 0500-6.0-12** 12.7 (0.5") 165 29 12 11.2 – MS 12 / T20
CBCYF 0500-6.0-12** 12.7 (0.5") 165 29 12 11.2 – MS 12 / T20
CBSFCY 16-150-16 16 170 52 16 14.4 – MS 16 / T20
CBCYF 16-150-16 16 170 52 16 14.4 – MS 16 / T20
CBSFCY 0750-8.0-18** 19.05/ (0.750") 225 38 18 17.95 – MS 20 / T20
CBCYF 0750-8.0-18** 19.05 / (0.750") 225 38 18 17.95 – MS 20 / T20
CBSFCY 20-200-20 20 225 77 20 18.0 – MS 20 / T20
CBCYF 20-200-20 20 225 77 20 18.0 – MS 20 / T20
CBSFCY 25-200-25 25 230 93 25 22.5 – MS 25 / T20
CBCYF 25-200-25 25 230 93 25 22.5 – MS 25 / T20
CBSFCY 1000-8.0-25** 25.4 (1.0") 230 47 25 22.5 – MS 25 / T20
CBCYF 1000-8.0-25** 25.4 (1.0") 230 47 25 22.5 – MS 25 / T20
CBSFCY 30-190-32 30 & 32 200 57 32 27.2 – MS 32 / T30
*- 6mm and 8mm diameter holders use new insert style . Part number VRBS and VBD.
**-Tools with smaller shank diameter than cutter diameter for full-length side clearance.
10 ***-Due to the delicate, slender design and the potential for misapplication of this tool, Millstar does not warrant this tool for breakage.
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Marathon Ball - MB Series

Copy Milling and Profiling Inserts
Millstar is proud to introduce a revolutionary insert designed to exceed today’s
stringent demands and surpass expectations while performing multi-axis
machining of dies, molds and similar free-form three-dimensional surfaces.
Millstar’s fully ground, 3-D helical design provides the end user the ability to
optimize operations in a variety of applications. The precision insert is located
by Millstar’s proven patented “V”-pocket clamping system. This advanced
design allows for unmatched repeatability and rigidity.
The unique cutting edge allows the Marathon Ball insert to perform in all
operations in materials below 42 HRc and in semi, and finishing operations above 42
HRc. The end user will notice significant benefits in heat treated intricate geometries as
well as some roughing applications. The insert geometry allows for smoother cutting
motion which in turn diminishes heat build up, tool deflection and reduces vibration
caused from the cutting action.
The versatility and ability to achieve superior surface finishes while increasing
metal removal rates makes the Marathon Ball the insert of choice for long, over
night, unattended runs in newer high velocity machines or older more
traditional equipment.

M E T R I C
Part Number D L Holder Type Insert Screw Insert Torx Key
MB 10 10 8,65 CY/TA MS 10 T15
MB 12 12 9,20 SFCY/SFTA MS 12 T20
MB 16 16 11,25 SFCY/SFTA MS16 T20
MB 20 20 13,15 SFCY/SFTA MS 20 T20
MB 25 25 18,25 SFCY/SFTA MS 25 T20
MB 30 30 22,15 SFCY/SFTA MS 32 T30
MB 32 32 21,95 SFCY/SFTA MS 32 T30

11
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STEEL SHANK TOOL HOLDERS

D2 .
STYLE CY/SFCY D2 STYLE TA/SFTA 6

D D1 D D1

L1
L1
L2
L2

Tool Size Ø Shank Ø Neck Ø Neck Length Total Length Use with Insert Insert
Ordering Nr. D D1 D2 L1 L2 Insert Style Screw Torx Key

CY 06-100-10 6 10 5,7 19 100 MS 06N T7

TA 06-095-12 6 12 5,7 30 95 MS 06N T7
TAV 06-095-12 NEW 6 12 5,7 30 95 MS 06N T7
TA 06-125-12 6 12 5,7 50 125 MS 06N T7
TA 06-150-10 6 10 5,7 25 150 MS 06N T7
TA 07-095-12 7 12 6,5 30 95 MS 06 T8
CY 08-100-10 8 10 7,5 19 100 MS 08N T7
TA 08-095-12 8 12 7,5 32 95 MS 08N T7
TAV 08-095-12 NEW 8 12 7,5 32 95 MS 08N T7
TA 08-150-10 8 10 7,5 25 150 MS 08N T7
TA 08-125-12 8 12 7,5 50 125 MS 08N T7
CY 10-100-10 10 10 9 19 100 MS 10 T15
CY 10-100-12 10 12 9 25 100 MS 10 T15
SFCY 10-100-10 10 10 9 19 100 MS 10 T15
SFCY 10-100-12 10 12 9 25 100 MS 10 T15
TA 10-125-12 10 12 9 35 125 MS 10 T15
TA 10-150-12 10 12 9 35 150 MS 10 T15
SFTA 10-100-12 10 12 9 35 100 MS 10 T15
SFTA 10-125-12 10 12 9 35 125 MS 10 T15
SFTA 10-150-12 10 12 9 35 150 MS 10 T15
SFCY 12-125-12 12 12 10,8 36 125 MS 12 T20
SFCY 12-150-12 12 12 10,8 46 150 MS 12 T20
SFTA 12-190-16 12 16 10,8 60 190 MS 12 T20
SFCY 14-125-16 14 16 12,6 36 125 MS 16 T20
SFCY 16-160-16 16 16 14,4 50 160 MS 16 T20
SFTA 16-190-20 16 20 14,4 57 190 MS 16 T20
SFCY 20-150-20 20 20 18 50 150 MS 20 T20
SFCY 20-190-20 20 20 18 61 190 MS 20 T20
SFTA 20-200-25 20 25 18 80 200 MS 20 T20
SFCY 22-200-25 22 25 19,8 50 200 MS 25 T20
SFCY 25-150-25 25 25 22,5 50 150 MS 25 T20
SFCY 25-200-25 25 25 22,5 64 200 MS 25 T20
SFCY 25-250-25 25 25 22,5 64 250 MS 25 T20
SFTA 25-250-32 25 32 22,5 100 250 MS 25 T20
SFTA 25-315-32 25 32 22,5 100 315 MS 25 T20
SFCY 30/32-190-32 30 & 32 32 27,2 57 190 MS 32 T30
SFCY 30/32-250-32 30 & 32 32 27,2 76 250 MS 32 T30
SFTA 30/32-250-40 30 & 32 40 27,2 120 250 MS 32 T30
SFCY 30/32-300-32 30 & 32 32 27.2 57 300 MS 32 T30
12 For your shrink fit and long reach requirements please see pages 10 & 19 for our carbide shank products.
 Warren MI 48092 USA
M E T R I C TEL (586)573-9450
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COPY MILLING & PROFILING INSERTS

RBS Precision ground, with special cutting
geometry. Finish die/mold steels, all ferrous VRBS Used for rough- to finish-milling small radius
or detail work, and surface milling in soft and
Small Ball Nose and non-ferrous materials and carbon Small Ball Nose hard steel, cast iron, aerospace and non-
Insert graphite. Insert ferrous alloys, graphite, etc. Suitable for high
speed and hard milling.
Part No. D L S D D
Part No. D L
D
RBS 06 6 7,73 4,73 VRBS-06 6 8,1
RBS 07 7 7,36 3,86
L
VRBS-08 8 4,5
RBS 08 8 7,00 3,00
These strong precision inserts are
L cost-effective replacements for
S solid carbide ball end mills.
2˚
For additional tool holders, see
6 8 page 10.

RB-R Precision ground, with positive ground

chipbreaker. Best for cavity and profile RB-N Precision ground, non-chipbreaker. Best
choice for cavity, core and profile milling of
Ball Nose Insert milling of soft tool and die/mold steels and Ball Nose Insert pre-hard and fully hard die/mold steels, cast
for all stainless steel (300, 400 and PH steels and cast iron. Strongest cutting edge
series), aerospace nickel and titanium alloys. design.
Part No. D L Part No. D L
D RB 10 R 10 9,50
D RB 10 N 10 9,50
RB 12 R 12 9,20 RB 12 N 12 9,20
RB 14 R 14 9,45 RB 14 N 14 9,45
RB 16 R 16 11,25 RB 16 N 16 11,25
L RB 20 R 20 13,15 L RB 20 N 20 13,15
RB 22 R 22 17,45 RB 22 N 22 17,45
RB 25 R 25 18,25 RB 25 N 25 18,25
RB 30 R 30 22,15 RB 30 N 30 22,15
RB 32 R 32 21,95 RB 32 N 32 21,95

BS-R Sidecutting with positive ground chipbreaker.

Side cutting insert used in cavity and core BS-N Sidecutting, non-chipbreaker. Side cutting
insert used in cavity and core profiling, for
Ball Nose Insert profiling, and for blending of fillets on softer Ball Nose Insert blending of fillets on medium and hard
materials. materials.

Part No. D L S Part No. D L S

D BS 10 R 10 9,50 3,65 D BS 10 N 10 9,50 3,65
BS 12 R 12 8,80 2,90 BS 12 N 12 8,80 2,90
BS 16 R 16 10,70 2,85 BS 16 N 16 10,70 2,85
BS 20 R 20 12,75 2,85 BS 20 N 20 12,75 2,85
L BS 25 R 25 17,20 4,85 L BS 25 N 25 17,20 4,85
S BS 30 R 30 20,00 5,10 S BS 30 N 30 20,00 5,10
BS 32 R 32 21,00 5,30 BS 32 N 32 21,00 5,30

RB-SF Precision ground, cutting on center, for semi-

finish and finish milling. Excellent choice for RB-NF Precision ground, with high positive
chipbreaker and clearance. Use this
SuperFinisher unattended finish milling at small depth and Ball Nose Insert aggressive, positive insert on all non-ferrous
Ball Nose Insert high speeds and feed rates. materials (aluminum, brass, copper, etc.)

Part No. D L Part No. D L

D RB 10 SF 10 8,65 D RB 10 NF 10 9,50
RB 12 SF 12 9,20 RB 12 NF 12 9,20
RB 16 SF 16 11,25 RB 16 NF 16 11,25
RB 20 SF 20 13,15 RB 20 NF 20 13,15
L RB 25 SF 25 18,25 L RB 25 NF 25 18,25
RB 30 SF 30 22,15 RB 30 NF 30 22,15
RB 32 SF 32 21,95 RB 32 NF 32 21,95

Please see page 11 for new Marathon Ball inserts. 13

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STEEL SHANK TOOL HOLDERS

D2 D2
STYLE CYF STYLE TAF 6
.

D D1 D D1

L1 L1
L2 L2

Tool Size Ø Shank Ø Neck Ø Neck Length Total Length Use with Insert Insert
Ordering Nr. D D1 D2 L1 L2 Insert Style Screw Torx Key

CYF 06-100-10 6 10 5,7 19 100 MS 06N T7

TA 06-095-12 6 12 5,7 30 95 MS 06N T7
TAV 06-095-12 NEW 6 12 5,7 30 95 MS 06N T7
TA 06-125-12 6 12 5,7 50 125 MS 06N T7
TA 06-150-10 6 10 5,7 25 150 MS 06N T7
TAF 06-150-10 6 10 5,7 25 150 MS 06N T7
CYF 08-100-10 8 10 7,5 19 100 MS 08N T7
CY 08-100-10 8 10 7,5 19 100 MS 08N T7
TA 08-095-12 8 12 7,5 32 95 MS 08N T7
TAV 08-095-12 NEW 8 12 7,5 32 95 MS 08N T7
TAF 08-150-10 8 10 7,5 25 150 MS 08N T7
TA 08-150-10 8 10 7,5 25 150 MS 08N T7
TA 08-125-12 8 12 7,5 50 125 MS 08N T7
CYF 10-100-10 10 10 9 19 100 MS 10 T15
CY 10-100-10 10 10 9 19 100 MS 10 T15
CY 10-100-12 10 12 9 25 100 MS 10 T15
TA 10-125-12 10 12 9 35 125 MS 10 T15
TA 10-150-12 10 12 9 35 150 MS 10 T15
TAF 10-150-12 10 12 9 35 150 MS 10 T15
CYF 12-125-12 12 12 10,8 36 125 MS 12 T20
CYF 12-150-12 12 12 10,8 46 150 MS 12 T20
TAF 12-190-16 12 16 10,8 60 190 MS 12 T20
CYF 16-160-16 16 16 14,4 50 160 MS 16 T20
TAF 16-190-20 16 20 14,4 57 190 MS 16 T20
CYF 20-150-20 20 20 18 50 150 MS 20 T20
CYF 20-200-20 20 20 18 61 200 MS 20 T20
TAF 20-200-25 20 25 18 80 200 MS 20 T20
CYF 25-150-25 25 25 22,5 50 150 MS 25 T20
CYF 25-200-25 25 25 22,5 64 200 MS 25 T20
TAF 25-250-32 25 32 22,5 100 250 MS 25 T20
TAF 25-315-32 25 32 22,5 100 315 MS 25 T20
CYF 30/32-190-32 32 32 28,6 57 190 MS 32 T30
CYF 30/32-250-32 32 32 28,6 76 250 MS 32 T30
TAF 30/32-250-40 32 40 28,6 120 250 MS 32 T30

For your shrink fit and long reach requirements please see pages 10 & 19 for our carbide shank products.

14
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BACK DRAFT, FLAT BOTTOM & TOROID INSERTS

Back Draft and Flat Bottom
inserts are used to best advantage ③ VBD Used for rough- to finish-milling small radius
or detail work, and surface milling in soft and
in applications where small corner Small Back Draft hard steel, cast iron, aerospace and non-
Insert ferrous alloys, aluminum alloys, graphite,
radii are required, for example etc. Suitable for high speed and hard milling.
finishing of straight and steep side walls,
Part No. D L R
blending and finishing of small corner VBD-06 6 8,6 0,4
radii, fillets and the like. Toroid Bull Nose D R VBD-08 8 5 0,4
Cutters combine the advantages of popular L
round insert toroidal “button cutters” and bull These strong precision inserts are
nose end mills with the proven design of Millstar’s 1˚
cost-effective replacements for
solid carbide ball end mills.
precision, single strong insert with twin-cutting
geometry. The result is reduced machining time and For additional tool holders, see
page 10.
enhanced accuracy and surface finish.
The inserts, and particularly the patented toroidal inserts, are
designed to improve 3- and 5-axis milling of dies, molds and similar
TO Precision ground, large corner radius & back
taper for spiral and pocket milling, milling of
Toroid Bull Nose pre-hard and hardened flat surfaces at higher
free-form three-dimensional surfaces. The precision ground inserts speeds than tools with smaller corner radii.
are held in Millstar’s proven rock-solid dovetail seat for superior Insert
Good choice for HS milling of Aluminum.
surface finish and machining accuracy. The insert designs avoid
the area of zero cutting speed at the tip of ball nose inserts for Part No. D L R
improved tool life. TO 6... 6 7,0 1,5
D TO 8... 8 7,0 2
R
The toroidal tools in particular have the advantage of cutting at TO 10... 10 8,65 3
larger step-over or pitch while leaving no or smaller cusps; the tools TO 12... 12 9,20 3
L TO 16... 16 11,25 4
also run at faster cutting speeds and feed rates. The toroidal bull
TO 20... 20 13,15 5
nose design simplifies 3- and 5-axis programming, works on a TO 25... 25 18,25 6
variety of materials from non-ferrous metal, carbon graphite and TO 30... 30 22,15 7,5
stainless steels to pre-hard and fully hard mold and die materials. TO 32... 32 21,95 8

FB-R Precision ground, with positive ground

chipbreaker. Flat bottom insert for shoulder FB-N Precision ground, non-chipbreaker. Flat
bottom insert for shoulder milling, fillet
Flat Bottom Insert milling, fillet finishing and long reach Flat Bottom Insert finishing and long reach angular wall
angular wall finishing of softer materials. finishing of hard materials.

Part No. D L R Part No. D L R

FB 06 R 6 7,0 0,4 FB 10 N 10 8,50 0,8
D FB 08 R 8 7,0 0,4 D FB 12 N 12 9,15 1
R FB 10 R 10 8,50 0,8 R FB 16 N 16 10,65 0,5 / 1,0 / 1,3
FB 12 R 12 9,15 1 FB 20 N 20 12,25 1,6
L FB 16 R 16 10,65 0,5 / 1,3 L FB 25 N 25 16,35 2
FB 20 R 20 12,25 1,6 FB 32 N 32 21,30 2,6 / 3
FB 25 R 25 16,35 2
FB 32 R 32 21,30 2,6

BD-R Precision ground, with positive ground

chipbreaker and 7 degree backtaper. Used for BD-N Precision ground, non-chipbreaker and 7
degree backtaper. Used for milling of cores,
Back Draft Insert milling of cores, cavities, fillets with straight Back Draft Insert cavities, fillets with straight or very steep
or very steep walls of softer material. walls of harder material.

Part No. D L R Part No. D L R

BD 06 R 6 7,5 0,4 BD 10 N 10 8,5 0,5 / 0,8
D BD 08 R 8 7,5 0,4 / 0,5 / 1,0 D BD 12 N 12 9,95 0,5 / 1 / 2
R BD 10 R 10 8,5 0,5 / 0,8 / 1 R BD 16 N 16 11,55 0,5 / 1 / 1,3 / 2 / 3
BD 12 R 12 9,95 0,5 / 1 BD 20 N 20 13,35 0,5 / 1 / 1,6 / 2 / 3
L BD 16 R 16 11,55 0,5 / 1,0 / 1,3 L BD 25 N 25 19,95 1/2
BD 20 R 20 13,35 1,0 / 1,6 BD 32 N 32 23,35 2,6
BD 25 R 25 19,95 1,0 / 2
BD 32 R 32 23,35 2,6

15
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& Modular Heads

L2
L

D2

D1
D

G1
L1

Solid Carbide Extension Shanks

Insert Ø Neck Ø Thread Shank Ø Total Length Length
Tool number D D2 G1 D1 (h6) L2 L L1

CY-10-150-SC-M6 6,8,10 9 M6 10 180 150 53

CY-12-150-SC-M6 6,8,10,12 10.8 M6 12 177 150 58
CY-16-200-SC-M8 16 14.4 M8 16 231 200 56
CY-20-200-SC-M10 20 18 M10 20 236 200 77
CY-25-250-SC-M12 25 22.5 M12 25 294 250 93
CY-32-300-SC-M16 32 28.6 M16 32 352 300 109
Note: Inch equivalent size tool heads fit metric tool extensions

STYLE CY...-SC STYLE TA...-SC STYLE CYF...-SC

6˚

G1
G1

G1
D

D
D

Screw-on Tool Heads

Tool number Insert Ø D Thread G1 Fits insert style Fits Shank Ø

TA-06-SC-M6 6 M6 10 & 12 / 0.500"

TA-08-SC-M6 8 M6 10 & 12 / 0.500"
CY-10-SC-M6 10 M6 10 & 12 / 0.500"
SFCY-10-SC-M6 10 M6 10 & 12 / 0.500"
CYF-10-SC-M6 10 M6 10 & 12 / 0.500"
SFCY-12-SC-M6 12 M6 12 (10) / 0.500"
CYF-12-SC-M6 12 M6 12 (10) / 0.500"
SFCY-16-SC-M8 16 M8 16 / 0.625"
CYF-16-SC-M8 16 M8 16 / 0.625"
SFCY-20-SC-M10 20 M10 20 / 0.750"
CYF-20-SC-M10 20 M10 20 / 0.750"
SFCY-25-SC-M12 25 M12 25 / 1.000"
CYF-25-SC-M12 25 M12 25 / 1.000"
SFCY-32-SC-M16 32 M16 32 / 1.250"
CYF-32-SC-M16 32 M16 32 / 1.250"
Note: Inch equivalent size tool heads fit metric tool extensions

17
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TOROID “BUTTON CUTTER” SHANK

AND ARBOR STYLE FACE MILLS
High Performance Milling from Heavy Roughing to Fine Finishing.
Millstar face mills are equally useful on newer high velocity machines and older slower
equipment and will optimize milling performance of all your machine tools. The
hardened tool bodies can be run at aggressive spindle speed and feedrates, when used
with Millstar’s precision ground, strong and thick, round inserts with our proven hard,
high performance TLN tool coating.
The tools provide for precision finish results, minimal tool deflection and run-out.
Excellent milling results can be achieved in roughing, semi finishing and fine finishing in
Z-level, profiling or raster cuts, as well as in linear or circular interpolation
milling or ramping.
The tools may be used with coolant, but we recommend dry, mist or
MQL (minimum quantity lubrication) milling with strong air blast when
high speed or hard machining steel, particularly in the higher hardness
range (> 45HRc / 425 HBN). Please refer to FAQs (frequently asked
questions) about milling on our website www.millstar.com.

Insert Style
S3

Tool Ordering Diameter Thickness Diameter

d1

S1
Number d S d1 Coating
15˚

S2 L2
FMI-12T3 12mm 3.97mm 3.9mm TLN d S

Arbor Style
10.2mm
22.0mm
Face D1
Cutting Neck No. Overall Insert Clamp Mounting
Tool Ordering Diameter Diameter of Length Insert Screw Screw Screw
Number D D1 Flutes L2 Required S1 S2 S3
FMA 50/5 50mm 40mm 5 50mm FMI-12T3 FMIS-1 FMIS-2 FMIS-3 D

FMA 52/5 52mm 40mm 5 50mm FMI-12T3 FMIS-1 FMIS-2 FMIS-3

FMA 63/5 63mm 40mm 5 50mm FMI-12T3 FMIS-1 FMIS-2 FMIS-3
STYLE 1 STYLE 2
L2 L2
S2 S2
L1 S1 L1 S1

D1 D2 D D1 D2 D

Shank Style
Tool Ordering Cutting Ø Shank Ø Neck Ø No. of Neck Length Shank OAL Insert Insert Screw Face Clamp Screw
Number D D1 D2 Flutes L1 Style L2 Required S1 S2
FM 25/2-180-25 25mm 25mm 23mm 2 100mm 1 180mm FMI-12T3 FMIS-1 FMIS-2
FM 32/3-180-25 32mm 25mm 24mm 3 42mm 2 180mm FMI-12T3 FMIS-1 FMIS-2
FM 32/3-180-32 32mm 32mm 29mm 3 100mm 1 180mm FMI-12T3 FMIS-1 FMIS-2
FM 40/4-180-32 40mm 32mm 31mm 4 42mm 2 180mm FMI-12T3 FMIS-1 FMIS-2
FM 42/4-180-32 42mm 32mm 31mm 4 42mm 2 180mm FMI-12T3 FMIS-1 FMIS-2 19
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• Square nose tools Series EMS / EIS with sharp corner or square
nose tools Series EIB / EMB with corner radius, all with medium-
high helix and strong cutting edges and tool body, work extremely
well in materials up to 65HRc as well as in softer materials.
• Ball nose tools Series BI / BM are designed with two flutes and
special nose geometry for true High Speed and Hard Material milling
up to 68 HRc. Ball nose tools are the most aggressive tools for these
applications. We will be glad to share our proven approach to
improving your machining results.
• A new Toroid Series TOI / TOM with large corner radius and slight
back taper is a Millstar innovative addition, and is very useful in I.D.
and O.D. Z-level and spiral milling at constant tool pressure, pocket
milling, and milling of pre-hard and hardened flat surfaces at higher
speeds than tools with smaller or sharp corner radii.
• Extended Reach ball nose tools Series BMNL and extended reach
square nose tools Series EMR are useful tools specifically designed
for long reach milling of extrusion dies, deep cavities and cores,
deep rib milling and similar applications. The reduced flute length
and neck diameter assure constant cutting pressure and minimal
tool deflection.

End Mills, Square End, Series EMS

Exalon (AlTiN)-Coated
Tool Cutter Diameter Corner Shank No. of Neck Cutting Nose Overall
Ordering Nr. tol. +0 /–0.01 Radius Diameter (h6) Flutes Diameter Length Taper Length
EMS-0.5-EX 0.5 – 6 3 0.5 1.5 7.5˚ / side 63
EMS-1.0-EX 1 – 6 4 1 3 7.5˚ / side 63
EMS-1.5-EX 1.5 – 6 4 1.5 4.5 7.5˚ / side 63
EMS-2.0-EX 2 – 6 4 2.0 6 7.5˚ / side 63
EMS-3.0-EX 3 – 6 5 3.0 9 7.5˚ / side 75
EMS-4.0-EX 4 – 6 6 4.0 12 7.5˚ / side 75
EMS-5.0-EX 5 – 6 6 5 15 – 75
EMS-6.0-EX 6 – 6 6 6 18 – 75
EMS-8.0-EX 8 – 8 6 8 24 – 90
EMS-10.0-EX 10 – 10 6 10 30 – 100
EMS-12.0-EX 12 – 12 6 12 36 – 100
End Mills, Square End Bull Nose,
with Corner Radius, Series EMB
Exalon (AlTiN)-Coated
Tool Cutter Diameter Corner Shank No. of Neck Cutting Nose Overall
Ordering Nr. tol. +0 /–0.01 Radius Diameter (h6) Flutes Diameter Length Taper Length
EMB-1.0-0.2-EX 1 0.2 6 4 1 3 7.5˚ / side 63
EMB-1.5-0.2-EX 1.5 0.2 6 4 1.5 4.5 7.5˚ / side 63
EMB-2.0-0.2-EX 2 0.2 6 4 2 6 7.5˚ / side 63
EMB-3.0-0.3-EX 3 0.3 6 5 3 9 7.5˚ / side 75
EMB-4.0-0.5-EX 4 0.5 6 6 4 12 7.5˚ / side 75
EMB-5.0-0.5-EX 5 0.5 6 6 5 15 7.5˚ / side 75
EMB-6.0-0.5-EX 6 0.5 6 6 6 18 – 75
EMB-6.0-1.0-EX 6 1 6 6 6 18 – 75
EMB-8.0-0.5-EX 8 0.5 8 6 8 24 – 90
EMB-10.0-1.0-EX 10 1 10 6 10 30 – 100
EMB-12.0-1.0-EX 12 1 12 6 12 36 – 100

End Mill, Ball Nose, Series BM

Exalon (AlTiN)-Coated
Tool Cutter Diameter Ball Shank No. of Neck Cutting Nose Overall
Ordering Nr. tol. +0 /–0.01 Radius Diameter (h6) Flutes Diameter Length Taper Length
BM 0.5 EX 0.5 0.25 6 2 – 0.5 7.5˚ / side 63
BM 1.0 EX 1 0.50 6 2 – 1.0 7.5˚ / side 63
BM 1.5 EX 1.5 0.75 6 2 – 1.5 7.5˚ / side 63
BM 2.0 EX 2 1.00 6 2 – 2.0 7.5˚ / side 63
BM 3.0 EX 3 1.50 6 2 – 3.0 7.5˚ / side 75
BM 4.0 EX 4 2.00 6 2 – 4.0 7.5˚ / side 75
BM 5.0 EX 5 2.50 6 2 – 5.0 7.5˚ / side 75
BM 6.0 EX 6 3.00 6 2 – 6.0 – 75
BM 8.0 EX 8 4.00 8 2 – 8.0 – 90
BM 10.0 EX 10 5.00 10 2 – 10.0 – 100
BM 12.0 EX 12 6.00 12 2 – 12.0 – 100
BM 16.0 EX 16 8.00 16 2 – 16.0 – 100
BM 16.0 EX-LL 16 8.00 16 2 – 16.0 – 150
22
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End Mill, Toroid, Series TOM

Exalon (AlTiN)-Coated
Tool Cutter Diameter Corner Shank No. of Neck Cutting Neck Length/ Overall
Ordering Nr. tol. +0 /–0.01 Radius Diameter (h6) Flutes Diameter Length Nose Taper Length
All tools backdraft 3 deg.
TOM 2.0 EX 2 0.5 6.0 2 1.84 2.0 6 / 7.5˚ 63
TOM 3.0 EX 3 0.5 6.0 2 2.76 3.0 9 / 7.5˚ 63
TOM 4.0 EX 4 1.0 6 2 3.68 4.0 12 / 7.5˚ 63
TOM 6.0 EX 6 1.5 6 2 5.52 6.0 18 / - 63
TOM 8.0 EX 8 2.0 8 2 7.37 8.0 24 / - 75
TOM 10.0 EX 10 2.5 10 2 9.21 10.0 30 / - 75
TOM 12.0 EX 12 3.O 12 2 11.05 12.0 36 / - 90

Ball End Mill, Extended Reach Tapered Nose,

Series BMNL 1.3 degree neck taper per side
Exalon (AlTiN)-Coated
Tool Cutter Diameter Ball Shank No. of Neck Cutting Neck Overall
Ordering Nr. tol. +0 /–0.01 Radius Diameter (h6) Flutes Dia. / Taper Length Length Length
BM-2.0-EX-1.25NL 2 1 6 2 1.9 / 1.3 2 31.75 / (1.25") 75
BM-2.0-EX-1.80NL 2 1 6 2 1.9 / 1.3 2 45.70 / (1.8") 75
BM-2.5-EX-1.25NL 2.5 1.25 6 2 2.4 / 1.3 2.5 31.75 / (1.25") 75
BM-2.5-EX-1.80NL 2.5 1.25 6 2 2.4 / 1.3 2.5 45.70 / (1.8") 75
BM-3.0-EX-1.25NL 3 1.5 6 2 2.9 / 1.3 3 31.75 / (1.25") 75
BM-3.0-EX-1.50NL 3 1.5 6 2 2.9 / 1.3 3 38.1 / (1.5") 75
BM-3.0-EX-1.80NL 3 1.5 6 2 2.9 / 1.3 3 45.70 / (1.8") 75
BM-3.0-EX-50NL 3 1.5 6 2 2.9 / 1.3 3 50 / (1.95") 75
BM-4.0-EX-1.25NL 4 2 6 2 3.9 / 1.3 4 31.75 / (1.25") 75
BM-4.0-EX-1.80NL 4 2 6 2 3.9 / 1.3 4 45.70 / (1.8") 75
BM-4.0-EX-50NL 4 2 6 2 3.9 / 1.3 4 50 / (1.95") 75
BM-5.0-EX-1.25NL 5 2.5 6 2 4.9 / 1.3 5 31.75 / (1.25") 75
BM-5.0-EX-1.80NL 5 2.5 6 2 4.9 / 1.3 5 45.70 / (1.8") 75
BM-6.0-EX-1.25NL 6 3 6 2 5.9 / - 6 31.75 / (1.25") 75
BM-6.0-EX-1.50NL 6 3 6 2 5.9 / - 6 38.1 / (1.5") 75
BM-6.0-EX-1.80NL 6 3 6 2 5.9 / - 6 45.70 / (1.8") 75
BM-8.0-EX-1.25NL 8 4 8 2 7.9 / - 8 31.75 / (1.25") 75

End Mill, Square End Bull Nose, with Corner

Radius, Extended Reach Tapered Nose,
Series EMR 1.3 degree neck taper per side
Exalon (AlTiN)-Coated
Tool Cutter Diameter Corner Shank No. of Neck Cutting Neck Overall
Ordering Nr. tol. +0 /–0.01 Radius Diameter (h6) Flutes Dia. / Taper Length Length Length
EMR-2.0-0.2-EX-1.25NL 2 0.2 6 4 1.9 / 1.3 2 31.75 / (1.25") 75
EMR-2.0-0.2-EX-1.80NL 2 0.2 6 4 1.9 / 1.3 2 45.70 / (1.8") 75
EMR-2.0-0.2-EX-50NL 2 0.2 6 4 1.9 / 1.3 2 50 / (1.95") 75
EMR-2.5-0.2-EX-1.25NL 2.5 0.2 6 4 2.4 / 1.3 2.5 31.75 / (1.25") 75
EMR-2.5-0.2-EX-1.80NL 2.5 0.2 6 4 2.4 / 1.3 2.5 45.70 / (1.8") 75
EMR-3.0-0.2-EX-1.25NL 3 0.2 6 5 2.9 / 1.3 3 31.75 / (1.25") 75
EMR-3.0-0.2-EX-1.80NL 3 0.2 6 5 2.9 / 1.3 3 45.70 / (1.8") 75
EMR-3.0-0.2-EX-50NL 3 0.2 6 5 2.9 / 1.3 3 50 / (1.95") 75
EMR-4.0-0.2-EX-1.25NL 4 0.2 6 6 3.9 / 1.3 4 31.75 / (1.25") 75
EMR-4.0-0.2-EX-1.80NL 4 0.2 6 6 3.9 / 1.3 4 45.70 / (1.8") 75
EMR-4.0-0.2-EX-50NL 4 0.2 6 6 3.9 / 1.3 4 50 / (1.95") 75
EMR-5.0-0.2-EX-1.25NL 5 0.2 6 6 4.9 / 1.3 5 31.75 / (1.25") 75
EMR-5.0-0.2-EX-1.80NL 5 0.2 6 6 4.9 / 1.3 5 45.70 / (1.8") 75
EMR-6.0-0.2-EX-1.25NL 6 0.2 6 6 5.9 / - 6 31.75 / (1.25") 75
EMR-6.0-0.2-EX-1.80NL 6 0.2 6 6 5.9 / - 6 45.70 / (1.8") 75
EMR-12.0-0.2-EX-1.25NL 12 0.2 12 6 11.9 / - 12 31.75 / (1.25") 75
EMR-12.0-0.2-EX-1.80NL 12 0.2 12 6 11.9 / - 12 45.70 / (1.8") 75

Safety Precautions
Grinding or other use of this tool may produce hazardous dust and fumes which may endanger health. To avoid adverse health effects, read the
material safety data sheet for this product, as well as for any cutting fluids or material coming into contact with this product – utilize adequate
ventilation and appropriate protection. Cutting tools may shatter when broken, wearing of eye protection is strongly advised in the vicinity of their use.
23
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MILLSTAR ENDMILL EXPANSION - METRIC

3 Flute Endmill, 45°- Aluminum - METRIC 3 Flute Ballnose, 45°- Aluminum - METRIC
Tool Cutter Corner Shank Cutting Total Tool Cutter Corner Shank Cutting Total
Ordering Diameter Radius Diameter Length Length Ordering Diameter Radius Diameter Length Length
Nr. tol. +0 /–.015 (R1) (D1) (L1) (L2) Nr. tol. +0 /–.015 (R1) (D1) (L1) (L2)
EMSA-04- 4 XX 4.000 14 50 BMA-03- 3 1.5 3.000 12 38
EMSA-06- 6 XX 6.000 19 63 BMA-04- 4 2 4.000 14 50
EMSA-08- 8 XX 8.000 22 63 BMA-06- 6 3 6.000 19 63
EMSA-10- 10 XX 10.000 25 63 BMA-08- 8 4 8.000 22 63
EMSA-12- 12 XX 12.000 25 76 BMA-10- 10 5 10.000 25 63
EMSA-16- 16 XX 16.000 38 88 BMA-12- 12 6 12.000 25 76
EMSA-20- 20 XX 20.000 38 101 BMA-16- 16 8 16.000 38 88
BMA-20- 20 10 20.000 38 101

2 Flute Endmills Long Series, Ball End - METRIC 4 Flute Endmills Long Series, Ball End - METRIC
Tool Cutter Corner Shank Cutting Total Tool Cutter Corner Shank Cutting Total
Ordering Diameter Radius Diameter Length Length Ordering Diameter Radius Diameter Length Length
Nr. tol. +0 /–.015 (R1) (D1) (L1) (L2) Nr. tol. +0 /–.015 (R1) (D1) (L1) (L2)
BM2-03-LL- 3 1.5 3 16 50 BM4-03-LL- 3 1.5 3 16 50
BM2-04-LL- 4 2 4 20 76 BM4-04-LL- 4 2 4 20 76
BM2-06-LL- 6 3 6 25 76 BM4-06-LL- 6 3 6 25 76
BM2-08-LL- 8 4 8 25 76 BM4-08-LL- 8 4 8 25 76
BM2-10-LL- 10 5 10 25 101 BM4-10-LL- 10 5 10 25 101
BM2-12-LL- 12 6 12 25 101 BM4-12-LL- 12 6 12 25 101
BM2-16-LL- 16 8 16 50 152 BM4-16-LL- 16 8 16 50 152
BM2-20-LL- 20 10 20 50 152 BM4-20-LL 20 10 20 50 152

4 Flute Variable Fluted Endmills, Square End

with 45° Chamfer - METRIC 220° - 2 Flute Endmills - Ball End - METRIC
Tool Cutter Corner Shank Cutting Total Tool Cutter Corner Shank Cutting Total
Ordering Diameter Radius Diameter Length Length Ordering Diameter Radius Diameter Length Length
Nr. tol. +0 /–.015 (R1) (D1) (L1) (L2) Nr. tol. +0 /–.015 (R1) (D1) (L1) (L2)
EMV4-03- 3 XX 3 16 38 BM220-03- 3 1.5 3 2.25 38
EMV4-04- 4 XX 4 20 50 BM220-04- 4 2 4 3.00 50
EMV4-06- 6 XX 6 25 63 BM220-06- 6 3 6 4.50 63
EMV4-08- 8 XX 8 25 63 BM220-08- 8 4 8 6.00 63
EMV4-10- 10 XX 10 25 63 BM220-10- 10 5 10 7.50 63
EMV4-12- 12 XX 12 25 76 BM220-12- 12 6 12 9.00 76
EMV4-16- 16 XX 16 50 88
EMV4-20- 20 XX 20 50 101

26
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2 Flute Endmills, Square End - METRIC 4 Flute Endmills, Square End - METRIC
Tool Cutter Corner Shank Cutting Total Tool Cutter Corner Shank Cutting Total
Ordering Diameter Radius Diameter Length Length Ordering Diameter Radius Diameter Length Length
Nr. tol. +0 /–.015 (R1) (D1) (L1) (L2) Nr. tol. +0 /–.015 (R1) (D1) (L1) (L2)
EMS2-01- 1* XX 3.000 4 38 EMS4-03- 3 XX 3.000 12 38
EMS2-02- 2* XX 3.000 8 38 EMS4-04- 4 XX 4.000 14 50
EMS2-03- 3 XX 3.000 12 38 EMS4-06- 6 XX 6.000 19 63
EMS2-04- 4 XX 4.000 14 50 EMS4-08- 8 XX 8.000 22 63
EMS2-06- 6 XX 6.000 19 63 EMS4-10- 10 XX 10.000 25 63
EMS2-08- 8 XX 8.000 22 63 EMS4-12- 12 XX 12.000 25 76
EMS2-10- 10 XX 10.000 25 63 EMS4-16- 16 XX 16.000 38 88
EMS2-12- 12 XX 12.000 25 76 EMS4-20- 20 XX 20.000 38 101
EMS2-16- 16 XX 16.000 38 88
EMS2-20- 20 XX 20.000 38 101

2 Flute Endmills Long Series, Square - METRIC 4 Flute Endmills Long Series, Square - METRIC
Tool Cutter Corner Shank Cutting Total Tool Cutter Corner Shank Cutting Total
Ordering Diameter Radius Diameter Length Length Ordering Diameter Radius Diameter Length Length
Nr. tol. +0 /–.015 (R1) (D1) (L1) (L2) Nr. tol. +0 /–.015 (R1) (D1) (L1) (L2)
EMS2-03-LL- 3 XX 3 16 50 EMS4-03-LL- 3 XX 3 16 50
EMS2-04-LL- 4 XX 4 20 76 EMS4-04-LL- 4 XX 4 20 76
EMS2-06-LL- 6 XX 6 25 76 EMS4-06-LL- 6 XX 6 25 76
EMS2-08-LL- 8 XX 8 25 76 EMS4-08-LL- 8 XX 8 25 76
EMS2-10-LL- 10 XX 10 25 101 EMS4-10-LL- 10 XX 10 25 101
EMS2-12-LL- 12 XX 12 25 101 EMS4-12-LL- 12 XX 12 25 101
EMS2-16-LL- 16 XX 16 50 152 EMS4-16-LL- 16 XX 16 50 152
EMS2-20-LL- 20 XX 20 50 152 EMS4-20-LL- 20 XX 20 50 152

4 Flute Tapered End Mill, Square End Rib Cutter - METRIC 4 Flute Tapered End Mill, Ball End Rib Cutter - METRIC
Tool Cutter Corner Shank Cutting Taper Total Tool Cutter Corner Shank Cutting Taper Total
Ordering Diameter Radius Diameter Length Angle Length Ordering Diameter Radius Diameter Length Angle Length
Nr. tol. +0 /–.015 (R1) (D1) (L1) (A) (L2) Nr. tol. +0 /–.015 (R1) (D1) (L1) (A) (L2)
EMT-1-01-8 1 xx 6 8 1 deg. 76 BMT-1-01-8 1 0.5 6 8 1 deg. 76
EMT-1-02-16 2 xx 6 16 1 deg. 76 BMT-1-02-16 2 1 6 16 1 deg. 76
EMT-2-01-8 1 xx 6 8 2 deg. 76 BMT-2-01-8 1 0.5 6 8 2 deg. 76
EMT-2-02-16 2 xx 6 16 2 deg. 76 BMT-2-02-16 2 1 6 16 2 deg. 76
Other Diameters, Tapers and Lengths available on request Other Diameters, Tapers and Lengths available on request

27
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INSERT STYLE & DESIGN

Full service roughing and finishing design with precision Heavy roughing design, precision ground, with
FS ground, sharp cutting edge. Very resistant to edge wear, cratering
and flank wear. Strong cutting edge and excellent chip control on heavy to
RG extra cutting edge protection for heavy cuts and
chiploads. Resistant to impact. Only available in larger insert
light chiploads. With TIN coating, this insert design is the general sizes. Please contact factory.
workhorse and the economical choice with the widest application range.
Aggressive high-positive cutting rake design with
This insert with TCN or TLN coating is usually the best choice for the
toughest applications in light to medium-heavy material removal. Refer to
additional information under “Coatings” below and the Millstar application
NF added clearance for free cutting of non-ferrous
materials, including aluminum, bronze, brass and copper alloys,
guidelines. Kirksite, Kayem, plastics, wood, etc.

Consult with us on any special needs or applications. We can tailor grades, geometry and special coatings to optimize your machining results.

COATINGS
NA Non-coated grade. The lowest cost choice.
May be used at normal speeds, or lower ALTiN-EXALON
speeds on older machines, for all purpose milling. May
be resharpened or altered. (TLN) Titanium aluminum nitride
advanced PVD coating. A
special, improved ALTiN coating approaching

TIN Titanium nitride multilayer PVD “gold”

coating. Adds lubricity, heat resistance, edge
and surface hardness. Machine at increased speeds and
feedrates with improved tool life. May be resharpened
and recoated. Not recommended on titanium.
Titanium carbo-nitride PVD multilayer
TCN coating. Higher hardness and toughness
than TIN. Choose on heavy cuts or high feeds and
speeds, preferably with coolant. Excellent crater and
wear resistance. Useful on abrasive and gummy
materials (cast iron, brass, aluminum alloys) and on stainless steels and
highly alloyed materials, including nickel and chrome based alloys.
Custom tool coatings for specific applications are available on request.
surface hardness of CBN on a tough substrate. Recommended for
tough and hard metal machining applications. When high cutting
temperatures are encountered the coating acts as a heat barrier,
protecting the cutting edge. This allows for aggressive, high speed
and dry milling so often encountered in today’s die and mold
machining. Use on tool, die and higher alloy steels, especially at
hardness over 40 HRc. Also appropriate for all stainless steels
(300, 400 and PH series), nickel alloys, titanium, nodular and
gray cast iron. Also useful in machining carbon graphite.
DMD Diamond coating. Custom coating for cutting
non-ferrous, non-metallic and very abrasive
materials at highly elevated speeds. Use on copper, bronze,
brass, aluminum-silicon alloys, carbon graphite, solid and fiber-
reinforced plastics, ceramics and composite materials.

FEED & SPEED CONSIDERATIONS

1. Step-over line milling at axial depth of cut 2. Sidemilling on steep walls 3. Corner radius milling
less than half the cutter diameter
FEED ROTATION ROTATION
FEED
FEED
FEED

ap D D=Dw
FEED

ae ae

Dw ae

Choose suitable feed and speed from
recommendations on page 21. These values
must be adjusted (increased), as only part
of the spherical cutter is used and the
effective cutting diameter (DW) is smaller
28 than the cutter diameter (D).
Choose suitable feed and speed from
recommendations on page 21. These values
do not need to be adjusted, as the working
diameter (Dw) is equal to the cutter
diameter (D). Climb mill whenever possible.
When milling with small axial width of cut (ae)
feed per tooth values are very high. To avoid
tool breakage, it is important to reduce the tool
feed when reaching the corner of a cavity, as
the engagement and the amount of material
removed increases dramatically.
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GENERAL FEED & SPEED RECOMMENDATIONS

The recommendations below are suggested parameters for use with Millstar Profile Milling Tools.
Start at a higher speed and lower feed value to avoid initial tool failure. Then adjust speed down and feed rate upward to achieve best metal
removal rate and tool life. Speed and feed rates should be adjusted downward to compensate for poor machine and set-up conditions (loose
spindles, machine ways and feedscrews), long tool reach, smaller insert diameter or full insert engagement. When ball nose inserts are used at
a depth of cut less than the full insert radius, the working diameter (Dw = effective cutting diameter) will be less than the insert diameter. Consult
tables A & B on page 25 to calculate speed and feed based on the working diameter used.

WORK MATERIAL HARDNESS CUTTING SPEED (SFM) FEED RATE (inch per tooth) PREFERRED GEOMETRY
HB HRc Conventional High Speed 1/4-3/8" 1/2-3/4" 1- 1 1/4"
Brinell Rockwell Mode (6-10 mm) (12-22 mm) (25-32 mm)
Carbon, Alloy and Tool
& Die Steels: 4130, P20, Use non-chipbreaker
H13, D2, A2, A5, D-M-E 50-200 400-840 to 1400 .001-.003 .002-.006 .003-.008 geometry, especially on pre-
No.1,2,3,5 275-320 28-34 360-700 to 1200 .001-.003 .002-.006 .003-.008 heattreated materials
Cast Irons: Grey 200 440-650 to 1200 .001-.004 .002-.008 .004-.012
300 32 380-430 to 1100 .001-.003 .002-.006 .004-.010 Use non-chipbreaker
Nodular/Ductile 200 400-640 to 1200 .001-.004 .002-.008 .004-.012 geometry
300 32 360-410 to 1100 .001-.003 .002-.006 .004-.009
Cast Steel, 200 430-720 to 1400 .001-.0025 .002-.0035 .003-.005 Use chipbreaker on softer,
low to medium carbon 250 22 400-700 to 1300 .001-.003 .002-.004 .003-.008 non-chipbreaker geometry on
300 32 250-500 to 1100 .001-.0025 .002-.0035 .003-.006 harder material
Stainless Steels:
Austenitic (300 Series) 300-620 to 1200 .0015-.004 .002-.007 .003-.010
Martenitic (400 Series) 220 300-520 to 1100 .0015-.003 .002-.006 .003-.008 Use chipbreaker inserts only
D-M-E No. 6, 7 300 32 300-440 to 1250 .0015-.003 .002-.006 .003-.006
Precipitation Hardening(PH) 350 38 300-410 to 1000 .0015-.003 .002-.005 .003-.006
Brass, Copper, Bronze, etc. 650+ .001-.003 .003-.007 .006-.010 Use TCN or TLN coating
Beryllium Copper Use chipbreaker inserts
Titanium (Alpha+Beta) Use TCN or TLN coating
Annealed <350 <38 140-375 to 800 .0015-.0035 .002-.005 .003-.008
Sol. Treated/aged <380 <41 130-300 to 650 .0015-.0035 .002-.005 .005-.007 Use chipbreaker
Nickel Based Alloys Use TCN or TLN coating and
(Inconel, K-Monel, Rene, 100-180 to 350 .001-.003 .002-.004 .003-.006 chipbreaker geometry
Hastelloy, Waspaloy)
Aluminum (<16% Si) 850+ .001-.004 .003-.012 .006-.020 Use NF geometry
Kirksite (Lead-Tin Alloy) 800+ .0015-.004 .003-.010 .006-.016 Use NF geometry
Wood 1000-2400 2500+ .002-.006 .002-.014 .005-.020 Use NF geometry
Carbon Graphite 1000-1600 2000+ .001-.008 .002-.015 .004-.020 Use N-FS or R-FS

For more aggressive speed & feed recommendations, please visit our website at http://www.millstar.com/application/app_aggr.htm
Calculation Example:
Operation: To mill P20 die steel at 300 BHN with a 1" dia. coated Millstar ball nose insert cutter at a depth of cut of .100"
Step 1 - Find speed range for die steel at 300 HB under column “cutting speed” (360-700 SFM) in above recommendations and choose an
above average starting speed as a starting value = 550 SFM. Choose a feedrate in inches per tooth (IPT) at the lower end of
corresponding feed range shown (.003-.008 IPT) = .004 IPT as starting value.
Step 2 - Determine the actual tool diameter engaged (working dia. Dw). If the depth of cut (DOC) is less than the full insert radius (as in our
example), go to Table A or C (following page) to find working diameter Dw. The working diameter for a 1" insert at .100" DOC is .600"
Dw. Calculate RPM on basis of Dw and SFM selected: Formula: SFM x 3.82 = 550 x 3.82 = 3501 RPM
Dw .600
Step 3 - If the depth of cut is less than the full insert radius (as in our example), the chipload (IPT) is reduced. Use the feedrate multipliers on
Table B (following page) to increase feedrate to compensate: Insert dia. 1" at DOC .100" = 1.67. Compensated feed rate: .004" x 1.67 =
.00668 IPT.
Result - Starting feed and speed values for above operation: 3500 RPM and .0067 IPT (rounded off). Feedrate IPM (inches per minute)
calculation: 3500 RPM x .0067 IPT x 2 Flutes = 46.9 IPM. All Millstar inserts are 2 Flute effective for balanced cutting and optimized feed.
Note: Follow all safety precautions. Do not run tools at high speeds unless special high velocity guarding and safety precautions are followed, and
toolholder with tool and insert are properly balanced. Contact factory for further information.
Safety Note: Tools can chip or fracture in use, always wear safety glasses, use machine guards and wear protective clothing. 29
 Warren MI 48092 USA
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GENERAL FEED & SPEED RECOMMENDATIONS (INCH & METRIC)

Table A: Working Diameter for Ball Nose Tools Table B: Feedrate Multiplier for Ball Nose Tools
Insert Diameter Insert Diameter
“D” .250 .312 .375 .500 .625 .750 1.00 1.25 “D” .250 .312 .375 .500 .625 .750 1.00 1.25
Depth Dw WORKING DIAMETER (inch) Depth FEEDRATE MULTIPLIER FACTORS
of cut (actual effective cutting diameter) of cut for Working Diameters Dw on Table A
.020 .135 .153 .169 .196 .220 .242 .280 .314 .020 1.85 2.04 2.22 2.55 2.84 3.00 3.75 4.00
.050 .200 .229 .255 .300 .339 .374 .436 .490 .050 1.25 1.36 1.47 1.67 1.84 2.00 2.29 2.55
.075 .229 .267 .300 .357 .406 .450 .527 .594 .075 1.09 1.17 1.25 1.40 1.54 1.67 1.90 2.10
.100 .245 .292 .332 .400 .458 .510 .600 .678 .100 1.02 1.07 1.13 1.25 1.37 1.47 1.67 1.84
.125 .250 .306 .345 .433 .500 .559 .661 .750 .125 1.00 1.02 1.06 1.15 1.25 1.34 1.51 1.66
.156 .312 .370 .464 .541 .609 .726 .827 .156 1.00 1.01 1.08 1.16 1.23 1.38 1.51
.188 .375 .484 .573 .650 .781 .893 .188 1.00 1.03 1.09 1.15 1.28 1.40
.250 .500 .612 .707 .866 1.00 .250 1.00 1.02 1.06 1.15 1.25
.312 .625 .739 .927 1.082 .312 1.00 1.02 1.08 1.15
.375 .750 .968 1.146 .375 1.00 1.03 1.09
.500 1.00 1.225 .500 1.00 1.02
.625 1.250 .625 1.00
For speed and feed calculations on Toroid Bull Nose Tools, use the information on previous page. For working diameter and feed rate multiplier
values, use Table C & D below when milling with Toroid tools.
Table C: Working Diameter for Toroid Tools Table D: Feedrate Multiplier for Toroid Tools
Insert Diameter Insert Diameter
“D” .375 .500 .625 .750 1.00 1.25 “D” .375 .500 .625 .750 1.00 1.25
Depth Dw WORKING DIAMETER (inch) Depth FEEDRATE MULTIPLIER FACTORS (inch)
of cut (actual cutting diameter of toroid inserts) of cut for Toroid Working Diameters Dw on Table C
.020 .260 .385 .465 .544 .696 .845 .020 1.85 1.85 2.04 2.22 2.55 2.84
.050 .325 .450 .541 .630 .800 .964 .050 1.25 1.25 1.36 1.47 1.67 1.84
.075 .354 .479 .579 .675 .867 1.031 .075 1.09 1.09 1.17 1.25 1.40 1.54
.100 .370 .495 .604 .707 .900 1.083 .100 1.02 1.02 1.07 1.13 1.25 1.37
.125 .375 .500 .618 .720 .933 1.125 .125 1 1 1.02 1.06 1.15 1.25
.156 .625 .745 .964 1.166 .156 1 1.01 1.08 1.16
.188 .750 .984 1.198 .188 1 1.03 1.09
.250 1.000 1.237 .250 1 1.02
.312 1.250 .312 1

Table A: Working Diameter for Ball Nose Tools Table B: Feedrate Multiplier for Ball Nose Tools
Insert Diameter Insert Diameter
"D" 6 8 10 12 16 20 25 30 32 "D" 6 8 10 12 16 20 25 30 32
Depth Dw WORKING DIAMETER (Metric) Depth FEEDRATE MULTIPLIER FACTORS
of cut (actual effective cutting diameter) of cut for Working Diameters Dw, Table A
0.5 3.3 3.9 4.4 4.8 5.6 6.2 7.0 7.7 7.9 0.5 1.8 2.0 2.2 2.5 2.8 3.2 3.5 3.8 4.0
1.0 4.5 5.3 6.0 6.6 7.7 8.7 9.8 10.8 11.1 1.0 1.2 1.5 1.6 1.8 2.0 2.2 2.5 2.6 2.8
2.0 5.7 6.9 8.0 8.9 10.6 12.0 13.6 15.0 15.5 2.0 1.0 1.1 1.2 1.3 1.5 1.6 1.8 1.9 2.0
3.0 6.0 7.7 9.2 10.4 12.5 14.3 16.2 18.0 18.7 3.0 .0 1.0 1.1 1.1 1.2 1.4 1.5 1.6 1.7
4.0 8.0 9.8 11.3 13.9 16.0 18.3 20.4 21.2 4.0 1.0 1.0 1.1 1.2 1.2 1.3 1.4 1.5
5.0 10.0 11.8 14.8 17.3 20.0 22.4 23.2 5.0 1.0 1.0 1.1 1.1 1.2 1.3 1.4
6.0 12.0 15.5 18.3 21.4 24.0 25.0 6.0 1.0 1.0 1.1 1.2 1.2 1.3
8.0 16.0 19.6 23.3 26.6 27.7 8.0 1.0 1.0 1.1 1.1 1.2
10.0 20.0 24.5 28.3 29.7 10.0 1.0 1.0 1.1 1.1
12.5 25.0 29.6 31.2 12.5 1.0 1.0 1.0
16.0 30.0 32.0 16.0 1.0 1.0

For speed and feed calculations on Toroid Bull Nose Tools, use the information on previous page. For working diameter and feed rate multiplier
values, use Table C & D below when milling with Toroid tools.

Table C: Working Diameter for Toroid Tools Table D: Feedrate Multiplier for Toroid Tools
Insert Diameter Insert Diameter
"D" 10 12 16 20 25 30 32 "D" 10 12 16 20 25 30 32
Depth Dw WORKING DIAMETER (Metric) Depth FEEDRATE MULTIPLIER FACTORS (Metric)
of cut (actual cutting diameter of toroid inserts) of cut for Toroid Working Diameters Dw, Table C
0.5 7.3 9.3 11.9 14.3 17.8 20.4 21.6 0.5 1.8 1.8 2.0 2.2 2.5 2.6 2.8
1.0 8.5 10.5 13.3 16.0 19.6 22.5 23.8 1.0 1.2 1.2 1.5 1.6 1.8 1.9 2.0
2.0 9.7 11.7 14.9 18.0 22.0 25.2 26.6 2.0 1.0 1.0 1.1 1.2 1.3 1.4 1.5
3.0 10.0 12.0 15.8 19.2 23.4 27.0 28.5 3.0 1.0 1.0 1.0 1.1 1.1 1.2 1.2
4.0 16.0 19.8 24.3 28.3 29.9 4.0 1.0 1.0 1.1 1.2 1.2
5.0 20.0 24.9 29.2 30.8 5.0 1.0 1.0 1.1 1.1
6.0 25.0 29.7 31.5 6.0 1.0 1.0 1.0
8.0 30.0 32.0 8.0 1.0 1.0
30
 Warren MI 48092 USA
TEL (586)573-9450
TOLL FREE 877-MILLSTAR
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FEED & SPEED CALCULATIONS

NOMENCLATURE Fzcor = feed/tooth, chip thinning corrected π = 3.14159...circle,
CF = centerline feed, helical interpolation circumference:dia. ratio
D = cutter/insert diameter x = multiplier symbol (inch) R th,ae = theoretical surface roughness in step-
Dw = effective cutter diameter • = multiplier symbol (metric) over direction
z = number of teeth ap = axial depth of cut R th,fz = theoretical surface roughness in
Vc = cutting speed ae = width of cut, step-over feed direction
n = number of revolutions per minute R = insert radius B = bore dia., helical interpolation
Vf = feed rate, or table feed SFM = surface feet per minute IC = inscribed circle (2 x R)
f = feed per revolution RPM = revolutions per minute Q = metal removal rate
fz = feed per tooth IPM = inch per minute, feed rate

CUTTING SPEED SPINDLE SPEED

To find the SFM of a cutter: To find the RPM of a cutter:
π x D x RPM RPM =
12 x SFM
=
3.82 x SFM
SFM = = 0.262 x D x RPM π x D D
12
Example: Example:
To find the SFM of a 3/4" Ø cutter rotating at 6000 RPM: To find the RPM of a 1/2" Ø cutter rotating at 800 SFM:
3.82 x 800
.262 x D x RPM = 0.262 x 0.75 x 6000 = 1179 SFM RPM = = 6112 RPM
.500
n • π • Dw
Metric Formula: vc = = m / minute vc • 1000
1000 Metric Formula: n = = min-1
π • Dw
FEED PER TOOTH
To find the feed per tooth of a cutter: FEED RATE OR TABLE FEED
To find the feed (table feed) in inches per minute:
IPM
FPT =
z x RPM IPM = RPM x f z x z
Example:
Example:
To find the feed per tooth of a two flute cutter rotating at 10000 RPM with a
To find the feed per tooth of a two flute cutter rotating at 5000 RPM with a feed
table travel of 240 inches per minute:
per tooth of 0.006:
240
FPT = = 0.012 FPT IPM = 5000 x 0.006 x 2 = 60 IPM
2 x 10 000
vf Metric Formula: v f = n • f z • z = mm / minute
Metric Formula: f = = mm / tooth
n • z

EFFECTIVE CUTTING DIAMETER, BALL NOSE EFFECTIVE CUTTING DIAMETER, TOROID

To find the effective cutter Ø of a Toroid bull nose tool:
To find the effective cutter Ø of a ball nose tool: ap

√R
D

√R Dw = 2 x 2
- (R - ap )2 + (D - 2R) R
Dw = 2 x 2
- (R - ap )2 D Dw
ap
Vf
Example:
Example: R
Dw To find the effective cutter diameter engaged of a
To find the effective cutter diameter engaged of a V1 3/4" Ø Toroid bull nose tool cutting at 0.100" depth of cut:
1.0" Ø ball nose tool cutting at 0.040" depth of cut:

Dw = 2 x √0.5 2
- (0.5 - 0.040)2 = 0.392" Dw = 2 x √ .1875 2
- (.1875 - .1)2 + (.75 - (2 x .1875)) = .707

Metric Formula: use same formula in mm. Metric Formula: use same formula in mm.

SURFACE ROUGHNESS, STEP-OVER SURFACE ROUGHNESS, FEED DIRECTION

To find the surface roughness in step-over direction: To find the surface roughness in feed direction:

R th,ae =
D
2
- √ D 4- a
2 2
e
R th,fz =
D
2
- √ D 4- f
2
z
2

Example:
Example:
To find the theoretical roughness of a 3/4" Ø ball nose tool in step-over
To find the theoretical roughness of a 3/4" Ø ball nose tool in feed direction of
direction of the cut (peak-to-valley or cusp height), with a 0.030 step-over
the cut (peak-to-valley or cusp height), with a 0.005 feed per tooth value:
value:

R th,ae =
.75
2
- √ .75 4- .03
2 2
= 0.0003" R th,fz =
.75
2
- √ .75 2
- .0052
4
= 0.000008"

Metric Formula: use same formula in mm. Metric Formula: use same formula in mm. 31
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AUTHORIZED DISTRIBUTOR

WORLD HEADQUARTERS
30200 Ryan Road
Warren, MI 48092 U.S.A.
Tel: (586) 573-9450
Toll Free: 877-MILLSTAR (877-645-5782)
Fax: (586) 573-9451
Email: info@millstar.com
Website: www.millstar.com

Catalog 2005 Printed and Manufactured in U.S.A. © Copyright 2005 Cole Tooling Systems