Aluminum milling — the 3 most common mistakes and how to prevent them

Anyone who mills aluminum knows the pitfalls: tools suddenly break, the surface becomes unsightly or the scrap accumulates — frustrating and expensive. But that doesn't have to be the case. With a little know-how, typical sources of error can be systematically eliminated.

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Here's how to specifically avoid these mistakes:

1. Incorrect cutting data leads to tool breakage, wear, bulging and poor surfaces.

SOLUTION:

· Select the appropriate cutting speed for the respective aluminum alloy

· Thin-walled parts: high feed rates, low cutting depth

2. Inadequate chip removal leads to adhesions on the cutting edge (built-up blade)

SOLUTION:

· Use coolant or MMS with the correct dosage and viscosity

· Polished panrooms and special coatings for non-ferrous processing

· Open space for better chip removal

3. Unsuitable tools are more likely to cause high tool wear, a bulging edge and poorer surface

SOLUTION:

· Select cutting tools for non-ferrous metals, if necessary with polished chip spaces and suitable coating

· Cutter1 up to max. 3 blades with large chip spaces

· Select a small wedge angle and positive rake angle when milling

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