As an important tool in milling, end mills play a vital role in aluminum alloy processing. Mastering the selection and use skills of end mills is crucial to improving processing efficiency, reducing processing costs, and ensuring processing quality. Aluminum alloys play an indispensable role in modern industry with their excellent properties such as light weight, high strength, and corrosion resistance. Its application fields are very wide, covering various industries such as aerospace, automobiles, construction, and electronics. With the continuous development of aluminum alloy materials, its types are becoming more and more diverse, which puts higher requirements on cutting processing technology.
End Mill Processing Pure Aluminum
Pure aluminum refers to a metal material with an aluminum content of more than 99%. It has excellent electrical conductivity, thermal conductivity and corrosion resistance, but low strength. Pure aluminum has low strength and is prone to plastic deformation and end mill tool adhesion during processing, posing a high challenge to cutting processing technology.
End Mill Processing 1050 Aluminum Alloy
Pure aluminum alloys with an aluminum content of 99.5% are often used in electrical and chemical equipment. The main difficulty in processing them is that the material is relatively soft and highly viscous, which makes it easy for the tool to stick during processing. It also easily generates a lot of heat during high-speed cutting, causing deformation of the workpiece.
Recommended Milling Cutter
- Carbide milling cutter: Use ultra-fine-grain carbide milling cutters (such as K10 or K20 carbide), which have high hardness and wear resistance and are suitable for machining aluminum alloys.
- Coated milling cutter: Choose tools with TiN (titanium nitride) or TiAlN (titanium aluminum nitride) coatings, which can reduce tool sticking, improve tool life and processing quality.
- Sharp milling cutter: Make sure the tool has large rake and clearance angles to improve cutting performance and reduce cutting forces.
Recommended Machining Parameters
- Cutting speed: 200-300 meters per minute (m/min), adjusted according to specific tool and machine conditions.
- Feed rate: 0.1-0.3 millimeters per revolution (mm/rev), adjusted according to specific process requirements and tool conditions.
- Cutting depth: 1-3 mm, to ensure stability and machining quality.
- Coolant: It is recommended to use emulsion or synthetic coolant to help dissipate heat and remove chips.
End Mill Processing 1060 Aluminum Alloy
Pure aluminum alloys with an aluminum content of 99.6% are often used in applications with high conductivity and high corrosion resistance. The difficulty of machining 1060 aluminum alloy with end mills is mainly due to the fact that the material is relatively soft and easily deformed during machining, and due to its high ductility, it is easy to produce burrs.
Recommended Milling Cutter
- Carbide end mill: Use PVD-coated ultra-fine grain carbide cutting tools (such as K20 carbide). This material has good wear resistance and anti-adhesion properties and is suitable for processing aluminum alloys.
- Coated milling cutters: Choose tools with DLC (Diamond Like Carbon) coating, which can significantly reduce tool sticking and improve tool life and surface quality.
- Sharp end mill: Make sure the rake angle and relief angle of the tool are large, with the rake angle above 12° and the relief angle above 20° to improve cutting performance and reduce cutting force and burr formation.
Recommended Machining Parameters
- Cutting speed: 250-350 meters per minute (m/min), adjusted according to the specific tool and machine conditions.
- Feed rate: 0.2-0.5 millimeters per revolution (mm/rev), adjusted according to the specific process requirements and tool conditions.
- Cutting depth: 1-2 mm, to ensure processing stability and reduce workpiece deformation.
- Coolant: It is recommended to use high-concentration emulsion or synthetic coolant, which helps dissipate heat, lubricate and remove chips, and reduce tool sticking.
End Mill Processing 1070 Aluminum Alloy
Pure aluminum alloys with an aluminum content of 99.7% have extremely high electrical and thermal conductivity and are often used in applications such as wires, cables, and radiators. The main difficulty in processing is the high ductility and low hardness of the material, which easily produces burrs and deformation during processing. By rationally selecting and using end mills, combined with effective processing technology, the difficulties in pure aluminum alloy cutting can be effectively overcome.
Recommended Milling Cutter
- Carbide cutting tools: Use fine-grained carbide cutting tools (such as H10 carbide). This material has higher hardness and wear resistance and is suitable for processing high-purity aluminum alloys.
- Coated tools: Choose tools with CrN (chromium nitride) coating. This coating has a low friction coefficient, which can significantly reduce tool sticking and increase tool life.
- Sharp tools: Make sure the rake angle of the tool is above 15° and the clearance angle is above 25° to improve cutting performance and reduce cutting force and burr formation.
Recommended Machining Parameters
- Cutting speed: 250-400 meters per minute (m/min), adjusted according to specific tool and machine conditions.
- Feed rate: 0.15-0.4 millimeters per revolution (mm/rev), adjusted according to specific process requirements and tool conditions.
- Cutting depth: 0.5-2 mm to reduce workpiece deformation and improve machining surface quality.
- Coolant: It is recommended to use high-efficiency coolant or synthetic coolant, which helps dissipate heat, lubricate and remove chips, reduce tool sticking and workpiece deformation.
End Mill Processing 1100 Aluminum Alloy
Pure aluminum alloy with an aluminum content of 99.0% has excellent corrosion resistance and high conductivity. It is often used in chemical equipment, food industry equipment and storage tanks. The main difficulty in processing lies in the low hardness and high ductility of the material, which easily produces burrs and uneven surfaces during processing, posing a high challenge to the processing technology and end mill tools.
Recommended Milling Cutter
- Carbide end mill: Use fine-grained carbide cutting tools (such as H20 carbide). This material has good wear resistance and cutting performance and is suitable for processing low-hardness aluminum alloys.
- Coated tools: Choose tools with ZrN (zirconium nitride) coating, which can significantly reduce sticking and provide a better surface finish.
- Sharp end mill: Make sure the rake angle of the tool is above 10° and the clearance angle is above 20° to improve cutting performance and reduce cutting force and surface defects.
Recommended Machining Parameters
- Cutting speed: 200-350 meters per minute (m/min), adjusted according to the specific tool and machine conditions.
- Feed rate: 0.1-0.4 millimeters per revolution (mm/rev), adjusted according to the specific process requirements and tool conditions.
- Cutting depth: 1-3 mm, to ensure processing stability and surface quality.
- Coolant: It is recommended to use emulsion or high-efficiency synthetic coolant, which helps to dissipate heat, lubricate and remove chips, and reduce sticking and workpiece deformation.
End Mill Processing Aluminum Copper Alloy
Aluminum-copper alloy is an aluminum alloy based on aluminum with copper as the main alloying element. It has high strength and good machinability. However, aluminum-copper alloy has poor corrosion resistance and is prone to problems such as tool sticking and built-up edge during cutting, which poses a high challenge to the end milling process.
End Mill Processing 2011 Aluminum Copper Alloy
Aluminum alloys with a high copper content have excellent cutting performance and high machining efficiency, and are often used in the manufacture of high-precision mechanical parts. The main difficulty in processing is that high heat is easily generated during the cutting process, causing deformation of the workpiece.
Recommended Milling Cutter
- Carbide end mill tools: Use medium-grain carbide tools (such as K30 carbide) with good wear resistance and thermal stability.
- Coatedend mill tools: Choose tools with TiCN (titanium carbon nitride) or TiAlN (titanium aluminum nitride) coatings, which can improve tool life and cutting performance.
- Sharp milling cutter tools: Make sure the tools are sharp to reduce cutting forces and improve surface finish.
Recommended Machining Parameters
- Cutting speed: 150-250 meters per minute (m/min), adjusted according to specific tool and machine conditions.
- Feed rate: 0.1-0.3 millimeters per revolution (mm/rev), adjusted according to specific process requirements and tool conditions.
- Cutting depth: 1-3 mm, to ensure processing stability and quality.
- Coolant: It is recommended to use high-efficiency coolant to help dissipate heat and remove chips.
End Mill Processing 2024 Aluminum Copper Alloy
Aluminum alloys with high copper content have high strength and good fatigue resistance and are often used in the manufacture of aerospace structural parts and mechanical parts. The difficulty in processing lies in the high hardness of the material and the heat accumulation generated during the cutting process, which leads to accelerated wear of the milling cutter.
Recommended Milling Cutter
- Carbide milling cutter: Use fine-grained carbide tools (such as K20 carbide) with high hardness and wear resistance.
- Coated milling cutter: Choose tools with TiAlN (nitrogen aluminum titanium) or AlTiN (nitrogen titanium aluminum) coatings, which can improve wear resistance and cutting efficiency.
- Sharp milling cutter: Ensure that the rake angle of the tool is above 12° and the back angle is above 20° to improve cutting performance and reduce heat accumulation.
Recommended Machining Parameters
- Cutting speed: 200-300 meters per minute (m/min), adjusted according to specific tool and machine conditions.
- Feed rate: 0.15-0.4 millimeters per revolution (mm/rev), adjusted according to specific process requirements and tool conditions.
- Cutting depth: 1-3 mm, to ensure processing stability and quality.
- Coolant: It is recommended to use high-efficiency coolant to help dissipate heat and chips.
End Mill Processing 2020 Aluminum Copper Alloy
A high-strength aluminum-copper alloy with good mechanical properties and fatigue resistance, commonly used in high-strength structural parts and aerospace applications. The difficulty in processing is that the high hardness of the material will cause heat accumulation during cutting and faster wear of the milling cutter tool.
Recommended Milling Cutter
- Carbide end mill tools: Use ultra-fine grain carbide tools (such as K10 carbide) with high hardness and wear resistance.
- Coated end mill tools: Choose tools with AlCrN (nitrogen chromium aluminum) or TiAlN (nitrogen aluminum titanium) coatings, which can improve wear resistance and reduce heat accumulation.
- Sharp end mill tools: Ensure that the tool rake angle is above 10° and the back angle is above 20° to improve cutting performance and reduce heat accumulation.
Recommended Machining Parameters
- Cutting speed: 150-250 meters per minute (m/min), adjusted according to specific tool and machine conditions.
- Feed rate: 0.1-0.3 millimeters per revolution (mm/rev), adjusted according to specific process requirements and tool conditions.
- Cutting depth: 1-2 mm to ensure processing stability and quality.
- Coolant: It is recommended to use high-efficiency coolant to help dissipate heat and chips.
End Mill Processing 2219 Aluminum Copper Alloy
High-strength aluminum alloys with high copper content have excellent high-temperature performance and corrosion resistance and are often used in the manufacture of structural parts in the aerospace field. However, high hardness and high thermal conductivity also cause a series of problems in the cutting process, which puts a severe test on milling cutter tools and processes.
Recommended Milling Cutter
- Carbide milling cutter: Use fine-grained carbide tools (such as H10 carbide) with high hardness and wear resistance.
- Coated milling cutter: Choose tools with AlTiN (nitrogen titanium aluminum) or AlCrN (nitrogen chromium aluminum) coatings, which can improve wear resistance and reduce heat accumulation.
- Sharp milling cutter: Ensure that the rake angle of the tool is above 12° and the back angle is above 20° to improve cutting performance and reduce heat accumulation.
Recommended Machining Parameters
- Cutting speed: 150-300 meters per minute (m/min), adjusted according to specific tool and machine conditions.
- Feed rate: 0.15-0.4 millimeters per revolution (mm/rev), adjusted according to specific process requirements and tool conditions.
- Cutting depth: 1-3 mm, to ensure machining stability and quality.
- Coolant: It is recommended to use high-efficiency coolant to help dissipate heat and remove chips.
End Mill Processing Aluminum Manganese Alloy
Aluminum-manganese alloy is a type of aluminum alloy, in which manganese is added. Manganese can improve the strength, corrosion resistance and welding performance of aluminum alloy. Aluminum-manganese alloy is one of the most widely used aluminum alloy series, widely used in construction, transportation, machinery manufacturing, aerospace and other fields.
End Mill Processing 3003 Aluminum Manganese Alloy
Aluminum alloys with a manganese content of about 1.2% have good corrosion resistance and formability and are often used in kitchenware, storage tanks, building decoration materials, transportation, and machinery manufacturing. The difficulty in processing is that the medium hardness of the material easily leads to heat accumulation, affecting the processing accuracy and surface quality.
Recommended Milling Cutter
- Carbide end mill tools: Use fine-grained carbide tools (such as K20 carbide) with good wear resistance and cutting performance.
- Coated milling tools: Choose tools with TiCN (nitrogen carbon titanium) or TiAlN (nitrogen aluminum titanium) coatings, which can improve wear resistance and cutting efficiency.
- Sharp milling tools: Ensure that the tool is sharp to reduce cutting forces and improve surface finish.
Recommended Machining Parameters
- Cutting speed: 200-300 meters per minute (m/min), adjusted according to specific tool and machine conditions.
- Feed rate: 0.1-0.3 millimeters per revolution (mm/rev), adjusted according to specific process requirements and tool conditions.
- Cutting depth: 1-3 mm, to ensure processing stability and quality.
- Coolant: It is recommended to use high-efficiency coolant to help dissipate heat and chips.
End Mill Processing 3004 Aluminum Manganese Alloy
Aluminum alloys containing manganese and magnesium have high strength and good corrosion resistance and are often used in beverage cans, chemical equipment and building materials. The difficulty in processing is that the medium hardness of the material will cause milling cutter tool wear, especially when high-speed processing, heat accumulation affects processing accuracy.
Recommended Milling Cutter
- Carbide milling cutter tools: Use fine-grained carbide tools (such as K20 carbide) with good wear resistance and cutting performance.
- Coated milling cutter tools: Choose tools with AlTiN (nitrogen titanium aluminum) or TiAlN (nitrogen aluminum titanium) coatings, which can improve wear resistance and cutting efficiency.
- Sharp milling cutter tools: Make sure the tool rake angle is above 12° and the back angle is above 20° to improve cutting performance and reduce heat accumulation.
Recommended Machining Parameters
- Cutting speed: 200-300 meters per minute (m/min), adjusted according to specific tool and machine conditions.
- Feed rate: 0.15-0.4 millimeters per revolution (mm/rev), adjusted according to specific process requirements and tool conditions.
- Cutting depth: 1-3 mm, to ensure processing stability and quality.
- Coolant: It is recommended to use high-efficiency coolant to help dissipate heat and chips.
End Mill Processing 3005 Aluminum Manganese Alloy
Aluminum alloys containing manganese and magnesium have good corrosion resistance and medium strength and are often used in car bodies, refrigeration units and building materials. The difficulty in processing lies in the medium hardness of the material, which easily generates heat during cutting, resulting in wear of the cutting tool and deterioration of the surface quality.
Recommended Milling Cutter
- Carbide milling cutter tools: Use medium-grain carbide tools (such as K30 carbide) with good wear resistance and cutting performance.
- Coated milling cutter tools: Choose tools with TiCN (titanium carbon nitrogen) or TiAlN (titanium aluminum nitrogen) coatings, which can improve wear resistance and cutting efficiency.
- Sharp milling cutter tools: Make sure the tool has a rake angle of more than 10° and a back angle of more than 20° to improve cutting performance and reduce heat accumulation.
Recommended Machining Parameters
- Cutting speed: 200-300 meters per minute (m/min), adjusted according to specific tool and machine conditions.
- Feed rate: 0.1-0.3 millimeters per revolution (mm/rev), adjusted according to specific process requirements and tool conditions.
- Cutting depth: 1-2 mm to ensure processing stability and quality.
- Coolant: It is recommended to use high-efficiency coolant to help dissipate heat and chips.
End Mill Processing 3104 Aluminum Manganese Alloy
Aluminum alloys containing manganese and magnesium have good corrosion resistance and medium strength, and are often used in beverage cans and building materials. The difficulty in processing is that the medium hardness of the material will cause heat accumulation, affecting processing stability and end mill tool life.
Recommended Milling Cutter
- Carbide cutting tools: Use fine-grained carbide tools (such as K20 carbide) with good wear resistance and cutting performance.
- Coated cutting tools: Choose tools with AlTiN (nitrogen titanium aluminum) or TiAlN (nitrogen aluminum titanium) coatings, which can improve wear resistance and cutting efficiency.
- Sharp cutting tools: Make sure the tool rake angle is above 12° and the back angle is above 20° to improve cutting performance and reduce heat accumulation.
Recommended Machining Parameters
- Cutting speed: 200-300 meters per minute (m/min), adjusted according to specific tool and machine conditions.
- Feed rate: 0.15-0.4 millimeters per revolution (mm/rev), adjusted according to specific process requirements and tool conditions.
- Cutting depth: 1-3 mm, to ensure processing stability and quality.
- Coolant: It is recommended to use high-efficiency coolant to help dissipate heat and chips.
End Mill Processing 3015 Aluminum Manganese Alloy
Aluminum alloys containing manganese have good corrosion resistance and medium strength and are often used in building materials and vehicle parts. The difficulty in processing is that the medium hardness of the material leads to heat accumulation and tool wear, which affects processing efficiency and quality.
Recommended Milling Cutter
- Carbide cutting tools: Use fine-grained carbide tools (such as K20 carbide) with good wear resistance and cutting performance.
- Coated cutting tools: Choose tools with TiCN (titanium carbon nitrogen) or TiAlN (titanium aluminum nitrogen) coatings, which can improve wear resistance and cutting efficiency.
- Sharp cutting tools: Make sure the rake angle of the tool is above 10° and the back angle is above 20° to improve cutting performance and reduce heat accumulation.
Recommended Machining Parameter
- Cutting speed: 200-300 meters per minute (m/min), adjusted according to specific tool and machine conditions.
- Feed rate: 0.1-0.3 millimeters per revolution (mm/rev), adjusted according to specific process requirements and tool conditions.
- Cutting depth: 1-2 mm, to ensure processing stability and quality.
- Coolant: It is recommended to use high-efficiency coolant to help dissipate heat and remove chips.
