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Drilling and cutting hardened steel without damaging tools starts with identifying the steel—not grabbing a generic metal bit. The right method depends on the grade, actual hardness, whether it is through-hardened steel or wear plate, and how rigidly the work and machine can be held. For drilling, manufacturer guidance favors a stable setup, material-specific tooling and controlled heat. For cutting, the available guidance does not establish a safe, general-purpose wheel or blade, so do not assume one cutting method fits every hardened steel.
What should you check before drilling or cutting hardened steel?
First identify the material and the job. “Hardened steel” is not one machining category: a wear plate such as Hardox and a through-hardened tool steel may have different machining requirements, even when their hardness figures seem similar. Find the grade and, if available, the hardness; then establish the hole diameter and depth or the cut’s purpose. If the grade is unknown, pause and ask the material supplier or a qualified tooling supplier to identify it before choosing a tool.
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Next assess the setup. Is the work going into a stationary drill press, a radial drilling machine or a CNC machine, or would the operation be handheld? Can the workpiece be clamped firmly? Can the cutting tool be kept short and supported, and can coolant reach the cutting area? These details matter because vibration, heat and unsuitable cutting data can damage tooling or compromise the operation. SSAB specifically advises against using a hand drilling machine for its hardened wear plate and describes stationary drilling under defined conditions instead (SSAB’s machine-selection guidance).
Do not choose a bit or cutting speed from a generic “metal” label alone. Use the drill or machine maker’s data for the exact tool and material. SSAB sums up the relationship for its products: “A harder steel will shorten tool lifetime. A lower cutting speed will do the opposite.” Its machining guidance is expressly limited to original SSAB products and intended for professional users; it is not a universal formula for every hardened alloy (SSAB’s machining FAQ).
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How does hardness change the machining decision?
Hardness is only one part of machinability. Two steels can have similar hardness readings but differ in alloy, heat treatment, toughness and tendency to work-harden. A wear plate may be engineered for abrasion resistance, while a through-hardened tool steel may behave differently at the cutting edge. Treat the grade, product form and hardness as a package when reading a toolmaker’s chart.
Hardness also affects the consequences of a poor setting. Excessive speed converts more of the cutting energy into heat; inadequate rigidity turns that heat and force into chatter, edge chipping or a wandering hole. SSAB’s concise rule—harder steel shortens tool life, while lower cutting speed extends it—does not replace a speed-and-feed table, but it explains why a conservative, controlled start is prudent for its products.
Do not compare tools by price, coating color or the word “industrial.” A solid-carbide drill intended for a particular hardened grade may be a good fit in a rigid CNC machine and a poor fit in a flexible handheld tool. Conversely, a cobalt drill can be appropriate in a narrowly defined Hardox application without being suitable for an unknown through-hardened alloy.
Which drill should you use?
For a stable machine setup and a known material, a solid-carbide drill rated by its maker for that steel is often the strongest direction in the available guidance. Carbide is not a cure-all: the machine, clamping, drill geometry and cutting data must suit the job. Cobalt or HSS options may fit narrower circumstances, but recommendations for Hardox must not be transferred automatically to through-hardened tool steel or another alloy.
| Situation | Supported tool direction | Important limit |
|---|---|---|
| Known hardened steel; rigid, stable machine | Consider a cemented-carbide drill whose maker specifies the material and application. SSAB lists solid-carbide, indexable-insert and exchangeable-head drill categories for stable Hardox drilling. | Confirm the exact grade, hardness, tool design and machine suitability with the tool manufacturer. Carbide selection depends on stable conditions. |
| Hardox on CNC with internal coolant | Dormer Pramet identifies solid carbide with internal cooling on CNC as often the most efficient Hardox option. | Its examples are product-specific. Use that drill maker’s cutting data for the exact tool and steel. |
| Hardox where CNC is unavailable | Dormer Pramet identifies HSCo cobalt drill options and emphasizes firm clamping, short overhang, abundant cooling and uninterrupted motion. | This is Hardox guidance, not a blanket recommendation for all hardened steels. |
| One hole in SSAB Hardox up to grade 500 on a stationary drill press or radial machine | SSAB allows HSS for this limited case at low cutting speed with ample cooling. | This narrow allowance applies to SSAB Hardox and the stated conditions. Do not generalize it to other steels at a similar apparent hardness. |
| Material harder than SSAB’s stated HSS allowance | SSAB calls for a solid-carbide or carbide-tipped drill; for stable machine conditions it recommends cemented carbide. | Check the material and tool makers’ guidance rather than treating a hardness threshold as universal. |
Haas Tooling’s catalog also distinguishes carbide drills for hardened steel from products described for pre-hardened steel, a useful reminder to read the application description rather than infer suitability from “carbide” alone (Haas Tooling’s solid-carbide drill listings). A tool’s material, coating or price does not establish that it is suitable for a particular grade or machine.
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Hole geometry matters as much as bit material. Tell the supplier the finished diameter, depth, number of holes and whether the hole is blind or through. A deep hole places more demand on chip evacuation and coolant delivery than a shallow hole; the correct response is to use the toolmaker’s geometry and data for that depth, not to improvise a longer bit with excessive unsupported length. If a long reach is unavoidable, ask specifically about an extended or exchangeable-head design and the rigidity required.
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Use this sequence only after confirming the drill is rated for the material and the machine can hold the operation steadily. Where guidance below is specific to Hardox, it is labeled as such; it should not be treated as a universal recipe for every hardened steel.
- Identify the steel and the operation. Record the grade and hardness, if known, plus the required hole diameter and depth. If you cannot establish what the steel is, get the material identified before selecting a drill or cutting data.
- Match the drill and data to the material. Check the drill maker’s application information and recommended speed and feed for the exact steel and tool. Do not carry a speed over from an easier steel category: Milwaukee’s 2026 HSS application guide separates recommendations by material category and hardness (Milwaukee’s HSS drill application guide).
- Choose a sufficiently rigid machine. For SSAB wear plate, its guidance rules out a hand drilling machine and describes stable, robust, sufficiently powerful stationary machinery. A handheld setup is not made suitable simply by fitting a more expensive drill.
- Clamp the workpiece firmly and minimize overhang. Secure the steel so it cannot move, and keep the drill as short and supported as the job permits. Dormer Pramet specifically recommends firm workholding and a short drill with minimal overhang for Hardox; its advice targets vibration control in that application (Dormer Pramet’s Hardox drilling guidance).
- Arrange appropriate cooling before starting. Use the coolant or emulsion specified for the tool, machine and material, and ensure it can reach the cutting zone. For Hardox drilling, Dormer Pramet calls for abundant cooling. Milwaukee’s guide states that “Coolants and lubricants will improve tool life by up to 5 times and workpiece finish”; this is Milwaukee Tool’s stated figure in its HSS guide, not a guaranteed or universal result.
- Start in the manner the toolmaker specifies. Dormer Pramet says not to pre-drill Hardox, apart from lightly centering with the correct point angle. Do not substitute a generic pilot-hole practice for that specific instruction, and do not assume it applies to other steel. Follow the drill’s prescribed point angle and starting method.
- Feed smoothly and continuously within the specified data. For Hardox, Dormer Pramet advises a smooth, non-stop drilling motion. Avoid stopping in a partly drilled hole and then trying to restart: the source warns that heat can harden the hole wall and restarting can cause severe tool wear. This is a specific warning about its Hardox drilling guidance.
- Stop if the tool jams or the setup becomes unstable. Do not keep forcing a jammed drill. Bosch’s power-tool manual advises switching off and investigating the cause; follow the manual for the particular machine, including its coolant-system and mounting requirements (Bosch Professional power-tool manual).
- Follow the safety instructions for every part of the setup. Use the protective equipment required by the tool, machine, coolant and workpiece manufacturers. Bosch gives additional requirements for its magnetic drill, including securing the tool for vertical, sloped or overhead work and checking coolant-system components; these instructions apply to that tool, not every drill.
Before the first production hole, verify that the workholding, coolant flow and tool runout are acceptable. A brief check can reveal a loose clamp, blocked nozzle or excessive overhang before a costly carbide edge is damaged. Keep the drill aligned with the spindle and avoid side loading; if alignment cannot be maintained, change the setup rather than compensating with hand pressure.
SSAB’s advice for milling wear plate harder than 400 HBW is related but should not be confused with drilling: it calls for a stable machine, firm clamping, a milling body with carbide inserts, a low initial cutting speed and the tool maker’s recommended feed. That recommendation supports a defined milling process, not a general drilling or cut-off method.
What cooling and lubrication actually do
Cooling is not an optional finishing step. It limits heat at the cutting edge, helps carry chips away and can reduce the chance that a hole wall becomes harder after an interruption. Dormer Pramet’s Hardox guidance calls for abundant coolant or emulsion, while Milwaukee’s 2026 HSS guide separates coolant and lubricant recommendations by material category and hardness.
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Use only the fluid and concentration approved for the machine, tool and workpiece. Direct the flow into the cutting zone rather than flooding an area the nozzle cannot reach. Check the reservoir, hose and nozzle before starting; a machine that is nominally equipped for coolant is not providing protection if the delivery path is blocked. Bosch’s manual gives tool-specific checks for coolant-system components, so those instructions take priority for its magnetic drill.
Milwaukee states that coolants and lubricants can improve tool life by up to five times and improve finish. That is the manufacturer’s figure for its HSS guide, not a promise for every steel, fluid or operating condition. If the toolmaker specifies dry cutting, minimum-quantity lubrication or a particular emulsion, follow that specification instead of applying a generic oil.
Why do drills burn, chip or stop cutting?
Common causes include a mismatch between drill and steel, excessive cutting speed, inadequate cooling, vibration, excessive tool overhang or an unsuitable machine. A drill that stops cutting is not proof that the answer is simply more pressure; forcing it can further damage the tool or work. Recheck the steel identity, drill rating, maker’s speed and feed, workholding and coolant delivery before deciding whether to continue.
- The bit will not bite or wears quickly: verify that the drill is rated for the actual grade and hardness. SSAB’s limited HSS allowance is only for a single hole in its Hardox up to grade 500 under specified stationary-machine, low-speed and ample-cooling conditions. Other cases may require carbide, but the tooling maker must confirm the match.
- The drill chatters or wanders: stop and improve rigidity. Check that the steel is firmly clamped, the machine is stable and the drill overhang is minimized. Dormer Pramet highlights all three factors for Hardox.
- The hole becomes difficult after a pause: for Hardox, Dormer Pramet warns that heat can harden the hole wall and that restarting a partly hardened hole can cause severe wear. Avoid interrupted motion; if a stop has occurred, do not simply force the same drill back into the hole.
- The drill jams: switch off and investigate rather than continuing to feed. Bosch’s manual says to switch off and look for the cause of a jam. Follow the relevant machine manual for safe recovery.
- The cut or hole overheats: verify coolant type and delivery against the tool and machine instructions, then check the cutting data. A coolant recommendation for one tool is not automatically correct for another.
- The hole exits with a damaged edge: confirm that the workpiece is supported beneath the exit and that the programmed feed and tool geometry match the application. Do not pull a long drill sideways to finish an exit; that side load can chip carbide.
How can you cut hardened steel without ruining a wheel or blade?
The available manufacturer guidance does not identify a general-purpose abrasive wheel or saw blade, or establish safe operating conditions for cutting through-hardened steel. It would be misleading to prescribe a wheel, tooth pitch, speed or cut-off method without knowing the steel, its hardness and the machine. Do not treat advice about carbide drilling or milling as proof that the same tooling is suitable for a saw or grinder.
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Before selecting a cutting process, tell a qualified tooling supplier or metalworking shop the steel grade and hardness, the section size, the cut location and finish required, and what equipment is available. Ask them to confirm the process, the specified consumable, machine compatibility and operating limits. If the grade or hardness cannot be verified, identify the material first. For wear plate, consult the manufacturer’s process guidance; SSAB’s carbide-insert advice above concerns milling under stable conditions, not an abrasive cut-off recommendation.
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This distinction matters because “cutting hardened steel” can mean substantially different operations. A recommendation for one process cannot safely be transferred to another based only on the word “hardened.” Where a supplier cannot verify a compatible setup, the safer practical choice is to have a metalworking service with appropriate equipment make the cut rather than sacrifice tools through trial and error.
For a milling operation on wear plate above 400 HBW, SSAB specifies a stable machine, firm clamping, a milling body fitted with carbide inserts, a low initial cutting speed and the insert maker’s feed recommendation. Those conditions describe controlled material removal with a milling body; they do not validate an angle grinder, reciprocating saw or bandsaw blade. Obtain a separate, process-specific recommendation for any of those methods.
Independent reader supportYour contribution helps us test, update, and keep practical guides available for everyone.What details should you give a tooling supplier?
A useful tooling recommendation depends on matching material, operation and machine—not on the steel label alone. Provide:
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- Whether the material is wear plate such as Hardox or a different through-hardened steel.
- For drilling: hole diameter, depth, number of holes and whether a through-hole or blind hole is required.
- For cutting: section dimensions, cut location and the finish or tolerance needed.
- Machine type and model where relevant, along with whether it is stationary, CNC or handheld.
- How the workpiece can be clamped, the tool overhang and what coolant delivery is available.
Ask the supplier to name the exact drill or cutting tool, application range, and corresponding speed, feed and coolant requirements. If the recommendation depends on a particular machine’s rigidity or coolant delivery, confirm those conditions are actually present before buying the tool or starting work.
When is outsourcing the sensible option?
Outsource the job when the grade or hardness is uncertain, the only available machine is handheld, the workpiece cannot be clamped securely, or the required cut has no supplier-verified tool and operating data. A specialist shop can identify the material, select a process and use the rigidity, coolant delivery and guarding that the operation requires. This is especially sensible for a one-off cut in expensive wear plate, where destroying several drills or wheels costs more than obtaining a controlled service.
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If you do proceed in-house, treat the first hole as a controlled trial only when the toolmaker has supplied applicable data. Inspect the tool after the trial, check the hole for abnormal work-hardening or edge damage, and stop if the machine, coolant or workholding does not match the documented conditions. Never turn an unverified setup into a production run simply because one hole appeared to work.
Frequently Asked Questions
Can I use a cobalt drill bit on any hardened steel?
No. Dormer Pramet identifies HSCo cobalt options for drilling Hardox when CNC is unavailable, but that is product-specific guidance. For another hardened alloy, confirm the drill’s rating and cutting data with its manufacturer.
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Give the supplier the steel grade and hardness, hole dimensions, machine type, workholding arrangement and coolant availability. If the grade is unknown, material identification should come before choosing the drill.
Does a carbide drill automatically work in a handheld drill?
No. The cited carbide recommendations are conditional on appropriate tooling and stable machine conditions, and SSAB does not recommend a hand drilling machine for its hardened wear plate. Check the tool and material makers’ guidance for the specific setup.
Can I use HSS for a hole in Hardox?
SSAB allows HSS only for a single hole in its Hardox up to grade 500, on a stationary drill press or radial machine, at low cutting speed with ample cooling. That narrow allowance does not apply automatically to another steel or to repeated production holes.
Should I make a pilot hole first?
For Hardox, Dormer Pramet says not to pre-drill, except for lightly centering with the correct point angle. Follow that specific instruction and the drill maker’s starting procedure; do not assume generic pilot-hole advice applies to every hardened steel.
The Bottom Line
Identify the steel and hardness first, then match a manufacturer-rated drill to a rigid, firmly clamped machine with the specified speed, feed and coolant. Carbide is favored for many stable Hardox and hardened-steel setups, while HSS and cobalt have narrower, product-specific uses. Keep the motion smooth, minimize overhang and stop when a tool jams. For cutting through-hardened steel, obtain a process-specific recommendation instead of guessing at a wheel or blade.
