Aluminium cutting

[Boyan Silyavski]

I find that Fz=D/100 usually too much. Especially about aluminum. Not talking about roughing bits. Tools 0-2mm is one thing, 3mm is another thing, 4-6 mm another, and so on.

I have Gwizard trial installed but some how this program doesn't engage me, may be the price and subscription put me off.
Just found the free online FSWizard and actually the data it gives is quite near the manufacturer data and very very near at my actual cutting data. So i am quite convinced and maybe even will buy the payed version

The bits i use are mainly Kyocera, razor sharp and polished. Now looking at their data below, some conclusions about how things develop with sizing and type of operation can be drawn. This is quite more realistic than others i have seen.





Vc - cutting speed
f - chip load or feed per tooth
Fr- feed rate mm/min
D- diameter of carbide bit
U- nimber of teeth on cutter
p=3.14


Ae - side removal
Ap - face removal


1.
determine spindle speed rpm/min depending an operation/roughing, slotting, finishing/


RPM=(Vc*1000)/(p*D)


2.


Calculate feed rate mm/min:


Fr=f*U*RPM

[AGTM]

Hi silyavski,

I checked carefully your post and the data which you provided. I completely agree with these parameters, but only if you do finishing. What I mean is that the roughing parameters provided in your table will be applied for finishing by me. I am working with Fz=D/100 and the tools (different range of diameters) sounds and works excellent. This is the tool: http://www.agtmcarbide.co.nz/product-category/agtm-tool-categories/aluminum-alloy-copper-alloy/endmill/aue-series/
In addition, this tool is designed for hard work and high MRR (material removal rate), but this cutter can be used for roughing and finishing as well. ST AUE has been designed for roughing, but it is doing a better finish than Kennametal.
I am attaching the manufacturer's cutting data for your reference. You will see there, that what I have recommended in my previous posts is actually low and safe. And it is because it is proven already by me.
I have sent a samples to JAZZCNC already, I will send you too to give it a try.
If you want to "make a step ahead", send me your address and let me know what diameter suits you.
Here are the cutting conditions: