Carbide vs. HSS End Mills for Aluminum Machining Which to Choose?

[Muzzer]

I prefer uncoated carbide with honed or "lapped" edges (= razer sharp!) and the only issue I've had has been when using high material removal rates rates - failure to clear the swarf can result in chips being dragged back into the cutting zone ("recutting"). This usually ends with the chips becoming welded to the tool, with a breakage following quickly afterwards. If you supply enough coolant and/or air to clear the chips, the material removal rate and surface finish are impressive.

I like the YG-1 Alu Power cutters https://www.cutwel.co.uk/milling-too...e51-yg-1-e5e51 and tend to buy them when they are on offer (buy 2 get one free etc) but there are similar ones available from Ali Express if you look carefully eg https://www.yuzemachinery.com/.

Many coated cutters actually stick to aluminium, so it's good to avoid them. And the cutting angles are different for aluminium and steel.

Here - have a laugh at this. Shows what happens when you fail to clear the chips (working into a corner like this was asking for recutting). I wouldn't attempt this now without using coolant and air.


And again:

[Chaz]

I prefer uncoated carbide with honed or "lapped" edges (= razer sharp!) and the only issue I've had has been when using high material removal rates rates - failure to clear the swarf can result in chips being dragged back into the cutting zone ("recutting"). This usually ends with the chips becoming welded to the tool, with a breakage following quickly afterwards. If you supply enough coolant and/or air to clear the chips, the material removal rate and surface finish are impressive.

I like the YG-1 Alu Power cutters https://www.cutwel.co.uk/milling-too...e51-yg-1-e5e51 and tend to buy them when they are on offer (buy 2 get one free etc) but there are similar ones available from Ali Express if you look carefully eg https://www.yuzemachinery.com/.

Many coated cutters actually stick to aluminium, so it's good to avoid them. And the cutting angles are different for aluminium and steel.

Here - have a laugh at this. Shows what happens when you fail to clear the chips (working into a corner like this was asking for recutting). I wouldn't attempt this now without using coolant and air.


And again:

Nice cutting on what looks to be slowish Speed (due to machine). Whats your DOC and Feed Rate please?