- Introduction
1.1 Background
In modern manufacturing, cutting tools are the core component for efficient and precise machining. With the continuous advancement of industrial technology, the requirements for machining efficiency, workpiece quality and tool life are increasing. Tools made of traditional materials can no longer meet the needs of complex working conditions. In this context, cemented carbide, as a high-performance material, has gradually become the mainstream choice for the manufacture of high-end cutting tools due to its excellent hardness, wear resistance and heat resistance. Especially in the fields of metal cutting, mold manufacturing, aerospace, etc., cemented carbide tools have become an indispensable machining tool due to their excellent performance. In 2025, with the in-depth development of intelligent manufacturing and automation technology, the demand for cemented carbide milling cutters continues to grow, and its application scenarios in precision machining are also expanding.
1.2 Theme Overview
Carbide milling cutter is a rotary cutting tool made of carbide material, which is widely used in milling of various materials. Its core feature is that it is made of tungsten carbide (WC) as the basis and an alloy material made of cobalt (Co) and other binders, which has the advantages of high hardness and durability. This article will comprehensively explore the definition of carbide milling cutter, introduce its physical properties, geometric characteristics and surface treatment technology in detail; analyze its classification method, including structure, use and coating type; explain the manufacturing process, application field, advantages and limitations in use; and provide precautions for use to ensure its safe and efficient application. Through this chapter and subsequent content, readers will have a deep understanding of the characteristics and applications of carbide milling cutters, so as to better integrate them into actual production.
- Definition of Carbide Milling Cutter
2.1 Basic definition of cemented carbide milling cutter
Cemented carbide milling cutter is a high-performance rotary cutting tool. Its cutter body and cutting part are made of cemented carbide material. It is widely used in precision machining of metals, alloys and some non-metallic materials. Cemented carbide is a composite material, mainly tungsten carbide (WC) as the hard phase, supplemented by metals such as cobalt (Co), nickel (Ni) or chromium (Cr) as the bonding phase, and sintered under high pressure (150-200 MPa) and high temperature (1350-1450°C) through advanced powder metallurgy process. This material gives the milling cutter an ultra-high hardness (usually reaching HV 1300-1800), which is significantly better than traditional high-speed steel (HSS), and has excellent wear resistance, high-temperature oxidation resistance (can stably work at 800-1000°C or even higher), and excellent resistance to mechanical stress, enabling it to cope with the processing needs of high-speed cutting, dry cutting and complex geometric shapes. The typical structure of a carbide milling cutter includes a cutting edge , a shank, a transition section, and an optional cooling hole design. The cutting edge can be designed as a straight tooth, a spiral tooth (angle range 15°-45°), a serrated or corrugated shape according to the processing requirements to adapt to different workpiece materials and processing accuracy. Its working principle is to remove material with a feed rate (fn) of 0.05-0.3 mm/tooth per tooth through high-speed rotation (the speed can reach 10,000-50,000 rpm, depending on the diameter and cutting speed). It is widely used in high – precision fields such as automotive manufacturing, aerospace, mold processing and the electronics industry. In 2025, with the increase in demand for miniaturized processing driven by 5G technology, the application of small-diameter models (diameter 0.5-2 mm) of carbide milling cutters in the field of micro-machining will increase significantly.
2.2 Differences between carbide milling cutters and other milling cutters
Carbide milling cutters show significant differences from other types of milling cutters in material composition, processing performance and application scenarios, laying the foundation for their unique positioning in modern manufacturing. First of all, compared with traditional high-speed steel (HSS) milling cutters, carbide milling cutters have overwhelming advantages in hardness, heat resistance and service life. The hardness of HSS milling cutters is generally HRC 62-66 (about HV 700-800), and the heat resistance is limited to about 600°C. Long-term high-temperature use will cause annealing softening, while the heat resistance of carbide milling cutters can reach more than 1000°C, especially after being equipped with TiAlN coating, the heat resistance is further improved to 1100°C, making it perform well under high-speed cutting ( Vc 50-200 m/min) or dry cutting conditions. In addition, the service life of carbide milling cutters is usually 5-10 times that of HSS milling cutters , significantly reducing the replacement frequency and production downtime. However, HSS milling cutters still occupy a certain market share in low-speed machining ( Vc < 30 m/min), intermittent cutting or small-batch production due to their lower manufacturing cost (about 1/3-1/5 of that of cemented carbide) and better toughness, and are widely used in small and medium-sized enterprises in developing countries.
On the other hand, compared with ceramic or diamond-coated tools, carbide milling cutters have their own advantages and disadvantages in performance and applicability. Ceramic milling cutters (such as alumina or silicon nitride-based) have higher hardness (HV 1800-2200) and wear resistance, and are suitable for ultra-high-speed cutting ( Vc > 300 m/min) and processing high-hardness materials (such as hardened steel HRC 60+), but they are relatively brittle (fracture toughness K ₁ c is about 3-5 MPa·m ¹ / ² ), prone to chipping under intermittent cutting or impact loads, and are expensive to manufacture (about 2-3 times that of carbide), limiting their popularity. Diamond-coated tools (such as CVD diamond) perform well in processing non-ferrous metals (such as aluminum alloys and carbon fiber composites), with wear resistance up to 10-20 times that of carbide , but their chemical affinity for iron -based materials leads to rapid wear, and the risk of coating peeling is high, and the cost is far higher than that of carbide (about 5-10 times). In contrast, carbide milling cutters have a fracture toughness ( K₁c 10-15 MPa·m¹ / ² ) that is more suitable for impact resistance, have relatively low manufacturing costs (approximately US$50-100 per cutter, depending on size and coating), and have significantly improved durability through PVD or CVD coating technology (such as TiN , AlCrN ) , making them an ideal choice for medium to high-demand machining tasks.
From a historical perspective, the development of cemented carbide milling cutters began in the early 20th century. German scholar Schroter first synthesized cemented carbide in 1923. After nearly a hundred years of technological iteration, cemented carbide tools gradually became the industry benchmark with the formulation of standards such as GB/T 14301 in 2008. In 2025, with the use of artificial intelligence to optimize cutting parameters and 3D printing technology for complex tool manufacturing, the customization of cemented carbide milling cutters will be further improved. For example, multifunctional composite tools designed for specific workpieces (integrating milling and drilling) show their adaptability in intelligent manufacturing. International standards such as ISO 6987 (hard material inserts) and DIN 844 (general technical conditions for milling cutters) also provide technical benchmarks for the global application of cemented carbide milling cutters, especially in the EU and North American markets, where market demand will increase by about 8% between 2024 and 2025, driving related R&D investment.
READ MORE: What is a Tungsten Carbide Milling Cutter?
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