routing aluminium help :)

[JAZZCNC]

I was cutting about 0.5mm depth at 7500mm/m with maximum spindle speed. I used a LOT of Wd40 and it got very hot.

I ran out of wd40 and clogged my tool before i was finished!

I'm using a 1.5kw spindle, using a 6mm end mill. 4 flute.

Bloody hell no wonder it got hot at 7.5mtr/min thats miles too fast for cutting Ali with a 4 flute cuttter. Wouldn't go much above 2.5mtr/min.!! Actually I wouldn't be using a 4 flute cutter full stop on Ali. Single flute cutters are far superior for cutting Ali.


My advise based on the fact I 95% cut Ali is.
No1 use single flute cutters on Ali, twin if cant get single but try stay away from multiflute.
No2 Don't be shy on the DOC you want a decent chipload so 1.5mm @ 650-700mm/min 12-13K rpm this will give a nice chipload the chips should be very hot but work piece only slightly warm. The goal is to get the heat to leave with the chips not stay in the work piece or tool, incorrect chipload is what causes chip sticking due to overheat.

To be honest it's trial and error to some degree and every machines sweet spot will be slightly different depending on how well built etc. . .BUt it's common for folks cutting Ali for first time to go too conservative on feeds and speeds, and esp DOC. Taking too little DOC actually heats the cutter quicker and causes sticking and wears tool away faster.

WD40 works good for coolant but better still is blown air with the odd squirt of WD40 has it clears the chips so your not recutting chips giving poor finish.
Also for best finish always finish off profiles with a slower 0.1mm full depth finish pass. The chips will look like little needles.!!