XG-402-16-BN
4 Flute Variable Helix Ball End Standard Length Tuffy Grade Carbide End Mill
0.5-in Dia 4-Flute End Mill, 1-in LOC, 0.5-in Shank, 3-in OAL, 0.25-in CR with Weldon Flats


4 and 5 flute variable-helix Tuffy grade end mills for titanium, steels, and high-temp alloys — corner-radius protected, AlTiN coated, with optional flats for high-torque cuts.
- Four sub-lines: XG-400 4-flute stub, XG-402 4-flute standard, XG-500 5-flute stub, XG-502 5-flute standard — plus XG-402-BN ball end; all variable helix to damp vibration and chatter
- Tuffy grade carbide, AlTiN (aluminum titanium nitride) coated, for titanium, cast iron, steel, stainless steel, and super alloys up to 40 HRc hardness
- Inch sizes 1/16"–1" (1/16"–1/8" ride on a 1/8" shank); metric MXG-402 runs 6–20 mm — marked NEW! with smaller sizes added
- Every size carries a corner radius, from .004 (1/16") to .028–.030 (3/4"–1"); metric .50–1.0 mm; custom radii to order by adding -CR and the size (e.g. XG-400-12-CR.050)
- Optional flats (-FL) on every inch size — 'Slippage? Tool Holder — Add Flats!' for high-torque cuts; metric tools do not have flats
- Guide guidelines: enter pockets by helical interpolation or ramping; profile milling preferred over slotting for highest MRR and tool life; climb milling recommended; use shrink-fit or equivalent holders (or flats); reduce feed 10% on ball-end tools
- Guide warning: published speeds & feeds assume very rigid machines, holders, and fixturing — extreme forces can be generated if conditions aren't appropriate
- Applications: slotting, side milling, helical interpolation, ramping, high-performance roughing, semi-finishing, finishing — dry, wet, cold air, or spray mist
- Anti-pull-out shanks: h5 tolerance on 1/4"–5/16", h4 on 3/8"–1" — tightest in the industry
- Tolerances: cutting dia −.001/−.002, shank −.0001/−.0002, flute length +.060/−.000 (MXG: cutting dia −.025/−.050 mm)
From the RobbJack Applications Guide.



About this series
XG / MXG Variable-Helix Steel End Mills
Variable-helix performance for steels and hi-temp alloys.
Variable-helix solid carbide end mills built for steels and high-temperature alloys — the variable geometry damps harmonics for chatter-free cuts and longer tool life.
- Variable helix for vibration-damped, chatter-free cutting
- Stub and standard lengths; square and ball-nose (-BN)
- Inch (XG) and metric (MXG)
Best for
- Steels
- High-temp alloys
- Slotting & profiling
Specifications
US machining terms with ISO 13399 codes.
- Cutting DiameterDC
- 0.5″
- Diameter ToleranceDC tol
- -0.0010/-0.0020
- Max Cutting DiameterDCX
- 0.499″
- Shank DiameterDMM
- 0.5″
- Length of Cut (LOC)APMX
- 1″
- Overall Length (OAL)OAL
- 3″
- Corner RadiusRE
- 0.25″
- Number of FlutesNOF
- 4
- Helix AngleFHA
- Variable
- Helix HandFHH
- Right-hand
- Cut Direction
- Right-hand cut
- End Type
- Ball End
- Center Cutting
- Yes — plunges
- Shank Flats
- Available (-FL)
- Series
- XG-402-BN — 4 Flute Variable Helix Ball End Standard Length Tuffy Grade Carbide End Mill
Cuts these materials
Applications
See it run
Tolerances
| Type | Min | Max |
|---|---|---|
| Cutting Diameter | -0.001 | -0.002 |
| Length of Cut | +0.06 | 0 |
| Overall Length | +0.06 | -0.06 |
| Shank Diameter | -0.0001 | -0.0002 |
Made & shipped in the USA · lead time confirmed at order. Buy at retail or through your distributor.
Performance guaranteed. Run it against the tool you use today — if it doesn't beat it, we'll make it right.
Adds Aluminum Titanium Nitride (AlTiN) · $165.55 — our pick for your material. Choose another finish below.
Proven in the field
- $548,290saved per year drilling carbon-fiber aircraft
- $216,000saved per year trimming aircraft skins
- 1,000%metal-removal increase in Inconel 718 (SPS)
Finishes (2)
XG-402-16-BN
$165.55
Available to order
XG-402-16-BN-FL
$165.55
Available to order
Starting at
$165.55
Performance guaranteed
More in the XG-402-BN series
Same series, different size — what changes from this tool is shown in red.
- XG-402-02-BN$38.75Ø 0.0625″LOC 0.1875″CR 0.0312″OAL 1.5″
- XG-402-03-BN$45.10Ø 0.0938″LOC 0.2812″CR 0.0469″OAL 1.5″
- XG-402-04-BN$46.65Ø 0.125″LOC 0.375″CR 0.0625″OAL 1.5″
- XG-402-06-BN$55.70Ø 0.1875″LOC 0.625″CR 0.0937″OAL 2.5″
- XG-402-08-BN$88.20Ø 0.25″LOC 0.75″CR 0.125″OAL 2.5″
- XG-402-10-BN$99.45Ø 0.3125″LOC 0.8125″CR 0.1563″OAL 2.5″
- XG-402-12-BN$128.05Ø 0.375″LOC 0.875″CR 0.1875″OAL 2.5″
- XG-402-20-BN$308.25Ø 0.625″LOC 1.25″CR 0.3125″OAL 3.5″
- XG-402-24-BN$388.10Ø 0.75″LOC 1.5″CR 0.375″OAL 4″
- XG-402-32-BN$631.10Ø 1″LOC 2″CR 0.5″OAL 5″
- XG-400-02$38.65Ø 0.0625″LOC 0.0938″CR 0.004″OAL 1.5″
- XG-400-03$38.65Ø 0.0938″LOC 0.1562″CR 0.005″OAL 1.5″