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09-02-2020 #10
It's mostly down to helix and if polished flutes or not. If you don't need flat bottom cutting then you are always better buying end mills like slot cutters which have more clearence.
For finish passes I actually prefer HSS as the slower feeds n speeds seem to give a better finish.
Yep it requires lots of chip clearing and it does come off like a fine slurry. I recently visited a place in Leeds who engrave and cut with tiny cutters using 100k+ HF spindles and what came off was like a fine grinding paste. Would you believe they hardly break cutters from actually cutting, they break them mostly when replacing or catching on stuff. However, they grind there own so it's no big deal to them.
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