The term "high-speed machining" in mold and die applications can actually mean two different things. Primarily, it means finishing operations at very high spindle speeds and super-high feedrates that provide machined surface finishes fine enough to dramatically reduce, or even eliminate,

secondary hand-finishing at the bench. In addition, however, the term can refer to heavy roughing cuts taken at accelerated metal removal rates.

  In this context, "button" cutters with round inserts have emerged as an important new moldmaking tool. Such cutters typically feature very thick, round inserts designed with patented integrated anvils for extra strength and security. Combined with special positive insert geometry, they are capable of very high metal removal rates.

  Button heads offered in modular two-piece endmills for mold and die operations make use of 0.500 inch and 0.750 inch diameter round inserts for facing, ramping and plunging. In machining deep, enclosed cavities, these tools can be run at up to four times the metal removal rates of other ballnose endmills. They also provide longer insert life than the ballnose cutters, which are sometimes subject to severe rubbing and chipping in these applications.         

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