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Machining Aluminum - Why It's Not So Simple

12/10/2019

by John Winebrenner

When it comes to machining aluminum, it’s not a simple task. There are many grades of aluminum, all of which have different recommended machining techniques. This tool tip helps break down some of the different grades of aluminum and our recommendations for tooling and surface feet per minute.

Fullerton Tool's AlumaMill series End Mills

1100 Grade Aluminum
This grade of aluminum is commercially pure aluminum and easy to machine though very ductile and difficult to control chips.
SFM = > 1000

2024 & 6061 Grades Aluminum
These grades are high strength and heat treatable aluminum alloys. They are very commonly used in Aircraft, Recreation, and Automotive body components.
SFM = > 600

7050 & 7075 Grades Aluminum
These grades are some of the highest strength aluminum alloys available. They are used in the manufacturing of Aircraft and Marine Vehicles.

This grade of Aluminum reacts much like tool steel when being machined. It is recommended to use high speed machining techniques when machining these materials. Using these types of techniques promotes the use of light radial cuts.
The use of heavier radial depths of cut and higher feed rates will promote the movement of the material due to the higher stress levels in the material.
Speeds – You can use higher SFM when machining these types of materials but you must use light RDoC and control the feed rates.

Cast Aluminum
A319 – 5% Silicon
Standard Tooling can be used very effectively.
A356 – 7% Silicon
Standard Tooling can be used very effectively.
A380 – 10.5% Silicon
PCD Tooling is the preferred tool for this material. TiB2 or ZrCN coatings must be used if using a carbide tool.
A390 – 17% Silicon
PCD Tooling or Coating is the only tool material that will effectively machine this grade of Aluminum. Lower SFM is preferred for this grade, < 1000 SFM.

Have more questions about machining aluminum?
Contact the Fullerton Tool team at 989.799.4550 or 855.722.7243.

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What Is A Controlled Root Tap?

12/9/2019

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First things first, what is the root of a tap?

The root of a tap is the surface at the bottom of the thread-form that connects adjacent thread flanks and is expressed as a width or as a diameter. The term root diameter is also called minor diameter, it’s one of those things, you say rain and I say precipitation, meaning the same thing...

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Machining Aluminum - Why It's Not So Simple

What Is A Controlled Root Tap?

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