A Comparative Analysis: How ExactaMill XE13 & XE22 Perform Against Industry Leaders

Developing the ExactaMill XE13 and XE22 Series stemmed from a recurring observation across aerospace and medical machining that many established end mills achieve acceptable results but there was clear room for optimization.

We introduced new geometries into customer processes already running leading-brand cutters, ensuring all conditions were held constant. When the early trials delivered promising changes in stability and tool longevity, we formalized a dedicated development program and expanded the scope of comparison.

Understanding Where Performance Diverges

While many tools claim optimal results on paper, their results differ significantly under high axial and radial loads, varying spindle ranges, high-chip-volume environments, etc. Ergo, we invested in features that control vibration, chip flow, and radius wear at the source - engineered flute geometry, a fully integrated corner radius, and a specialized cutting edge.

The data collected across multiple platforms - Makino MAG-series, multi-spindle gantries, and heavy aluminum applications - provides a clear technical comparison between Exactaform and the brands most widely used in these sectors.

Competitor 1: Titanium and Aluminum Machining Benchmarks

Across multiple controlled trials against Competitor 1, Exactaform XE22 and XE13 demonstrated consistent advantages in tool life, radial engagement capability, and overall process reliability. All tests were performed under real production conditions, using matched parameters wherever possible to ensure comparability between tools and platforms.

• 30% longer tool life in direct plug-and-play testing
• 20% longer life on multi-spindle gantry applications
• Improved productivity via increased radial engagement and reduced passes
• 2× tool life on high-speed finishing operations
• Stable, consistent performance across multiple machine platforms

Competitor 2: Aluminium Machining Benchmarks

On SNK’s machining of Boeing 737 and 777 window frames, Competitor 2’s tool performance deteriorated rapidly. The cutters exhibited chatter from the start of the process, created significant burr formation, and reached end-of-life at approximately 1,500 minutes, resulting in additional time spent deburring and reworking. Replacing the tool with an Exactaform XE13 three-flute design with enhanced flute geometry, improved corner-radius protection, and the DLC coating produced a clear operational difference.

• Predictable stability, with no chatter throughout the machining process
• Zero burr formation, eliminating downstream deburring time
• 2× tool life, extending from 1,500 minutes to over 3,000 minutes
• Improved reliability due to enhanced flute geometry and corner-radius integrity
• DLC coating, contributing to reduced wear and clean material evacuation

Competitor 3: Deep Pocketing Stability Benchmarks

On a Makino EX-3 producing hinge and latch deep pockets for the Boeing 777, Competitor 3’s tool, a 1.0" three-flute cutter with ZRN coating and corner radius of 0.060" and 0.120", exhibited persistent chatter due to the extended 7" stick-out required for the part. This instability affected both surface integrity and dimensional accuracy. Replacing the tool with an Exactaform XE13 two-flute finisher, designed with an alternative flute geometry and supplied uncoated for optimal edge retention, immediately eliminated chatter and stabilized the process.

• Chatter eliminated despite a 7-inch stick-out, a major cause of instability in deep pockets
• Improved dimensional accuracy through enhanced flute geometry and core rigidity
• Uncoated tool performance exceeded coated alternative, demonstrating geometry-led stability
• Superior edge control, particularly around the corner radius where the competitor tool failed

Competitor 4: Titanium Material Removal Rate Benchmarks

On this trial, the customer’s existing tool, a 0.75" six-flute cutter with a 0.120" radius, was run at 350 SFM with an axial depth of cut of 1.0", a radial engagement of 0.070", and a feed rate of 53.5 IPM. Under these conditions, the process achieved a metal removal rate (MRR) of 3.7 in³/min and yielded approximately 1.5 hours of tool life. After reviewing the application, Exactaform recommended an adjusted strategy using XE22, maintaining the same axial engagement but reducing SFM to 285, increasing chip load to 0.005 per tooth, and increasing the radial engagement to 0.200". This made the feed rate 43.5 IPM, which produced an MRR of 8.7 in³/min, while extending tool life to 5 hours.

• MRR increased from 3.7 to 8.7 in³/min, a 2.4× improvement in productivity
• Tool life extended from 1.5 to 5 hours, a 3.3× increase
• Optimized radial engagement provided greater efficiency without compromising stability
• Lower SFM improved thermal control, reducing premature edge wear

Why ExactaMill XE13 & XE22 Provide a Measurable Advantage

The performance data across all four comparisons shows a consistent pattern: the XE13 and XE22 series deliver higher stability, longer tool life, and greater process efficiency than the industry-leading cutters they were benchmarked against.

As Mike Herle, Solid Round Cutting Tools Manager Exactaform USA Inc. explains: “Most end mill cutters are ok for normal conditions, until the operations optimization demands stable, consistent, long-lasting end mills to push the limits of machining, for greater productivity. What we set out to build with the XE Series is a tool that stays stable and predictable exactly when the operational demand increases, that’s where customers see the real value.”

For teams looking to reduce operational risk, improve consistency, or validate the XE Series in their own machining environment, our US technical group is available to review applications and arrange trials.

Contact the US Team:

📧 sales.usa@exactaform.com
📞 (615) 624-8709