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8-FLUTE HSS ENDMILL FOR ALUMINUM?

01/05/2022 10:00 AM

Will I have any issues using this 2" dia. 30º 8-flute endmill to square-up some aluminum rec tube? I need to take off about .025 from each side. Could you suggest a feed/speed to try? I have this and a fly cutter available, to use. The fly cutter is a bit slow... unless I'm not using the proper speed/feed. I have a sizable production run to make and would like to do it as efficiently as possible. Thanx!

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#1

Re: 8-FLUTE HSS ENDMILL FOR ALUMINUM?

01/05/2022 10:19 AM

"What speed should you mill aluminum?

Instead, any milling process run at around 15,000 rpm or higher is likely to offer some optimum spindle speed, a "sweet spot," where the cut is significantly more stable than it is at both higher and lower speed settings." Jan 15, 2001

https://www.mmsonline.com/articles/maximum-aluminum

https://www.harveyperformance.com/in-the-loupe/flute-count-matters/

https://www.dapra.com/resources/milling-formulas

https://www.youtube.com/channel/UCc2lUKVOTXKlQR7Fm7h1JfQ

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#2
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Re: 8-FLUTE HSS ENDMILL FOR ALUMINUM?

01/05/2022 10:26 AM

My biggest ignorance in this are the 8-flutes. I've not used them on aluminum before, and would be using a 2 or 3 flute if I was to buy a new tool. But this is what I have on hand, and am thinking a standard feed/speed might not be quite right in this situation on aluminum.

I did read the flute article you sent, which just makes me wonder more if 8 flutes on aluminum should be handled differently.

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#3
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Re: 8-FLUTE HSS ENDMILL FOR ALUMINUM?

01/05/2022 10:44 AM

I might agree with you, it would seem to me a slower speed would be prudent... Is this an enclosed system with a cooling stream? Tungsten carbide would probably be better with a smaller bit and less flutes and higher speed....Heat would seem to be the only problem in any case...perhaps you could monitor the temperature and attempt to set the speed that way...? I would start slow, how low can you go?

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#4
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Re: 8-FLUTE HSS ENDMILL FOR ALUMINUM?

01/05/2022 11:07 AM
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#11
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Re: 8-FLUTE HSS ENDMILL FOR ALUMINUM?

01/06/2022 12:46 PM

The calculator says 535 RPM. I'll see how that works.

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#12
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Re: 8-FLUTE HSS ENDMILL FOR ALUMINUM?

01/06/2022 1:41 PM

Normally, when questionable, what one would do is calculate chip load per tooth…

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#5

Re: 8-FLUTE HSS ENDMILL FOR ALUMINUM?

01/05/2022 11:25 PM

Use plenty of coolant, the heat generated will partially melt the aluminum. And will gum up The flutes and gullets. And vacuum or air to keep the shavings out of the way.

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#6

Re: 8-FLUTE HSS ENDMILL FOR ALUMINUM?

01/06/2022 12:06 AM

Skip to 3:08

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#7

Re: 8-FLUTE HSS ENDMILL FOR ALUMINUM?

01/06/2022 2:04 AM

What machine are you using to run this tool, and what is the maximum rpm and what size of tool holder (cat 40 etc). Also what is the size of tubing and wall thickness? If I know a bit more info I can give you a good starting point. That cutter isn’t ideal but for its size and no more than you are taking off and especially that you’re end cutting, it will definitely save you some time over a single tooth fly cutter if those are your only options. Generally wouldn’t want that many flutes but as big as that cutter is and the nature of your cut you won’t have any chip clearing issues. Main thing will be for it to be sharp as possible to keep temps lower at the cut along with good coolant pressure.

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#9
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Re: 8-FLUTE HSS ENDMILL FOR ALUMINUM?

01/06/2022 8:18 AM

I just started working for a fabricator and 99.9% of what we do is using a chop saw on aluminum and welding it. This is the single time we use a mill, so we're not really set up or supplied very well in that area. Therefor... no coolant system. Just a guy standing there with a spray bottle of WD40. And there isn't really an actual machinists here.

That endmill has never been used, so it's very sharp. They didn't even know they had it until I went digging around in our supplies and found it, after watching the slow progress using the fly-cutter.

It's an old manual Bridgeport that we have. The tubing is actually square. 2 x 2 x 1/8 wall. Machining just two sides to get it square leaves two unacceptably thin walls, so we have to do all four, and it's taking far more time than it should per part, for such a basic task. So looking to tighten up wherever possible with our limited tooling and crude set-up.

I was a machinist for several years, but it was 40 years ago, so I've forgotten the finer points of the craft; like how to set things for an 8-flute and a spray bottle coolant system, and get the best efficiency possible.

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#13
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Re: 8-FLUTE HSS ENDMILL FOR ALUMINUM?

01/06/2022 2:30 PM

Hey, I see you're the new guy; with your first post! Welcome to the club. Your post was very helpful to me. I appreciate it.

Welcome to a club that only includes the meanest, grouchiest, most arrogant sons & daughters a bitches, ya ever did see. Most of em are lucky they have this place, cuz they no longer fit into society.

Have fun!

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#17
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Re: 8-FLUTE HSS ENDMILL FOR ALUMINUM?

01/07/2022 4:04 AM

How dare you, I'm not arrogant, I'm just right all the time.

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#19
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Re: 8-FLUTE HSS ENDMILL FOR ALUMINUM?

01/17/2022 6:46 AM

Judge not,lest you be judged likewise.

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#8

Re: 8-FLUTE HSS ENDMILL FOR ALUMINUM?

01/06/2022 3:56 AM

We use a very similar 1.5" cutter on aluminium 6061/6082 without any problem. use plenty of coolant & you may have to play with speeds & feeds to get the optimum cut.

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#10
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Re: 8-FLUTE HSS ENDMILL FOR ALUMINUM?

01/06/2022 12:40 PM

Thanx Nigh.

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#14

Re: 8-FLUTE HSS ENDMILL FOR ALUMINUM?

01/06/2022 2:45 PM

Well that is going to definitely limit you. Sorry I thought you were on a cnc. If it is something you do often you could get one of the little mister coolant systems made for knee mills. With that small of cut you may be fine without depending on the alloy and how gummy it is. I would stub the tool up as far as you can and lock the quill all the way up and bring the part up with the knee if possible and run the max rpm your mill will dependably run and feed it as hard as it will take. Rigidity is going to definitely be the limiting factor there but you can't go too fast on the spindle on that machine. Every machine and setup has different areas of resonance that you will hit so a lot of combinations will work fine and you can move the quill 1/4" and it could be at a position that it totally changes where it runs good at. Personally we usually run rpm as fast as we can and then play with feed to run as fast as the machine and setup will allow. Running a job now that is at 12000rpm and 800ipm feed just because we are limited by machine but it runs great. Good luck with it!

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#16
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Re: 8-FLUTE HSS ENDMILL FOR ALUMINUM?

01/07/2022 4:03 AM

I was looking at coolants recently & saw that you can get spray bottles of foam coolant. I haven't tried it but they claim that it clings to the cutter better than liquids.

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#15

Re: 8-FLUTE HSS ENDMILL FOR ALUMINUM?

01/06/2022 6:07 PM

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#18
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Re: 8-FLUTE HSS ENDMILL FOR ALUMINUM?

01/07/2022 11:06 AM
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