Both indexable and solid carbide tools have advantages and disadvantages. In some cases, such as when using an end mill to finish the bottom of a pocket or an indexable face mill to deck off the top of a part, selecting the appropriate tool for milling can be simple.

When Should You Choose A Solid Carbide Tool Over An Indexable Milling Cutter?

Although numerous elements exist to consider, and each circumstance should be evaluated individually, price and reliability spring to mind when selecting when to utilize an indexable or solid carbide tool. 

The cost of replacing a solid carbide tool may exceed the 1/2"-5/8" range. At this point, indexable tooling should start to be taken into account. Even though indexable tooling can be used on diameters as small as 3/8", the cost advantages may not always be apparent. Cutting diameter sizes between 5/8" and 3/4" is where you start realizing good financial gains.

However, you might not base your decision on the initial dollar amount. The advantages of the cost savings could be outweighed by process reliability improvements such as chip management, tool adjustments, or using a more durable (reliable) setup. 

Small, challenging-to-manage chips produced by solid carbide end mills have the potential to damage or lengthen the time needed for maintenance in places like way covers. But because of the feed rate and cut depth, chips made with indexable tooling are typically heavier and easier to handle. Changes in the tools used can also make a difference.

A deciding aspect may be the capacity to change insert corners after a particular lot or amount for process dependability, even though tooling with sophisticated coatings typically has excellent tool life. Additionally, indexable tooling provides a variety of radii, coatings, and substrates (such as PCD) that may enhance your application.

Advantages and Disadvantages of Solid Carbide and Indexable End Mill Tools

Solid Carbide Tooling

Advantages

• These premium end mills can be reground and are ground to the tightest tolerances.
• This can result in better finishes. (Precise.)
• Small diameters are readily available.
• Replacement costs for smaller sizes are generally minimal.
• Reduced force on the tool
• Able to cut deeper depths.

Disadvantages

• If you chip or crash, your options for regrinding may be limited to replacing the entire end mill (brittle).
• Limited capacity for feed rates.
• There are a few larger sizes.
• The cost of larger diameters may increase.
• Tools with little runout might be time-consuming or expensive to set up. This can result in tiny, unmanageable chips.

Indexable End Mill Tooling

Advantages

• Typically, inserts are ground.
• They can include PCD inserts for finishes that resemble mirrors.
• Bigger diameters are available.
• Replacement inserts are significantly less expensive, and each insert can be indexed to produce several cutting edges.
• Can withstand increased load and disruption.
• Greater feed rates are possible, and thicker and more controllable chips are produced.

Disadvantages

• Tolerances on holders are typically looser.
• The price of PCD inserts varies.
• There are fewer smaller sizes.
• Initial costs may be higher because some inserts are only offered in packages.
• Increased tool pressure
• It needs more power to operate.

Many CNC milling machine operators will express different opinions regarding their preferred type of cutting tool for a specific application because they tend to rely on tactics that have worked in the past. It is possible to achieve even better results by making a more informed choice of solid carbide.

Choosing the right tool is essential, and we at SCTools strive to provide you with the knowledge and experience to help you make the best choice for your application.

If you have any questions about carbide cutting tools, end mills, drills, etc. be sure to reach out to us @ sctools.co/Home or call us at (877)737-0987. We help you machine better!