New End Mill Line is a Star Performer

5 June 2025

TaeguTec has now expanded its renowned StarMill SED 7 range of solid carbide end mills with the introduction of two advanced variants designed to enhance machining performance. The 4XD long type and the chip splitter type have been introduced to provide unparalleled efficiency when machining difficult-to-cut materials such as titanium alloys and stainless steel, offering increased productivity, improved surface finishes and longer tool life.

The TaeguTec StarMill SED 7 solid carbide end mills have already established a strong reputation in the industry due to their innovative 7-flute design, unequal spacing of cutting edges, and optimised helix angle. This combination delivers outstanding surface quality and higher material removal rates. The introduction of the 4XD long type and the chip splitter type further broadens the operational capabilities of the SED 7 line, allowing manufacturers to tackle more complex machining requirements with greater ease.

The 4XD long type end mill has been engineered to handle greater depths of cut, making it ideal for operations requiring extended axial engagement. Its enhanced design ensures stability and precision even in demanding applications, delivering consistent results across a wide range of machining tasks. The StarMill 4XD long series is available in diameters ranging from 6 to 20mm, featuring a 0.5mm corner radius to maintain durability during heavy-duty machining. With flute lengths ranging from 15 to 80mm and an overall length of 57 to 150mm, the robust end mills can reach the deepest cavities while retaining optimal machining parameters.

Similarly, the StarMill chip splitter type end mills are available with diameters from 6 to 20mm and a flute length from 15 to 80mm. Optimised for rough machining and high-feed applications, the StarMill chip splitter features an overall length ranging from 57 to 150mm, with a particularly thick core that ensures remarkably low cutting forces and exceptional chip evacuation. This combination reduces heat buildup and minimises tool wear with swarf removal enhanced by a 38-degree high-helix flute angle. By minimising chip volume and effectively controlling chip formation, the chip splitter series ensures smoother operation and longer tool life.

One of the most distinctive features of the two new additions to the StarMill SED 7 line is the 7-flute design with unequal cutting edge spacing that significantly reduces vibration and noise. The optimised helix angle, calibrated explicitly for titanium alloys and stainless steel, further boosts the line’s performance, enabling higher feed rates with minimal deflection. The result is a substantial increase in productivity while maintaining precision and quality.

Field tests and case studies have demonstrated the superiority of the expanded SED 7 line over its competitors. In a recent study conducted on titanium alloy (Ti-6Al-4V), the TaeguTec TT5515 grade SED 7120-4D-N achieved remarkable results, delivering an 82% increase in productivity by enabling higher material removal rates (MRR) while extending tool life by 50%. The field test also highlighted reduced noise levels and significantly better surface finishes when compared to rival product lines.

The use of TT5515 grade further ensures superior wear resistance and effective heat management, contributing to extended tool longevity and reliable performance under demanding conditions.

The expanded StarMill SED 7 line is ideally suited for applications across multiple industries. Aerospace and automotive manufacturers can leverage their capabilities to machine titanium and stainless-steel components with reduced cycle times. Medical device manufacturers, on the other hand, will benefit from the high-accuracy performance delivered by the new variants, especially when working with difficult-to-machine alloys. General engineering applications also benefit from the versatility and precision, making it an ideal choice for slotting, trochoidal machining, and high-feed milling operations.