4 TIPS FOR NEXT LEVEL PERFORMANCE IN ALUMINUM MACHINING

Harmonics, chip evacuation, chatter and surface finish quality can easily become a big problem due to the machinability and setups associated with the machining aluminum components.

Not all 2 and 3 flute solid carbide end mills are created equal, but they are by far the most used end mills when it comes to milling non-ferrous materials such as aluminum. Harmonics, chip evacuation, chatter and surface finish quality can easily become a big problem due to the machinability and setups associated with the machining aluminum components.

1. NEED FOR SPEED BUT WATCHOUT FOR CHATTER BUMPS

Because aluminum is free machining, it gives the illusions that we can program max rpm and max feed rate on our CNC milling machines and everything will work out just fine, right? Unfortunately, chatter, vibrations, harmonics or whatever you want to call it, tend to rear their ugly faces, and can leave us scratching our heads in disbelief. The new A245/A345 product families are uniquely designed to address these major issues by incorporating a Cylindrical Margin on the OD, coupled with a unique flute shape and high shear geometry, this product family reduces power consumption and cutting pressure, while increasing chip control. By utilizing these new Niagara Cutter product families in your aluminum machining, you can increase your cutting speeds and feeds without sacrificing surface quality, resulting in reduced cycle times and increase productivity.

2. WHY SO SERIOUS ABOUT CHIP CONTROL

Let’s talk about the elephant in the shop, chip control is a big issue when it comes to machining aluminum. Aluminum by nature is what some people call “gummy” or “sticky,” which cases built up edge (BUE) when milling, drilling, tapping, you name it. BUE can cause premature tool failure, surface quality issues and even power consumption increases. Keeping this BUE in mind, the R&D engineers at Niagara Cutter, a Seco Tools company, developed a truly unique polished K-land, using a new PVD style coating called Aluminum Non-Ferrous (ANF), on the radial rake face to help reduce and, in some cases, eliminate BUE entirely.

3. AS THEY SAY, HAPPY COOLANT, HAPPY LIFE

With all the different types of water soluble and oil-based coolants in the industry, varying concentration levels, etc., it can sometimes when trying to determine what coolant is best suited for your specific needs.

Pro Tip: Taking the time to do research online or talking to your colleagues in the industry can help narrow down your selections. Reach out to the Seco Tools technical support team if you want additional support!

Once you’ve identified the right coolant for your application, it is crucial to follow the manufactures recommendation when it comes to maintaining the proper concentration levels and establish a coolant maintenance/care plan. Failing to do this can result in lost production due to inconsistent tool life caused by BUE, part quality fluctuations and overall cost increases.

4. HOLD ON

It’s a misconception that machining aluminum “easy” as it holds different challenges than those of other materials like pH Stainless steels, titanium alloys and hardened tool steel. No matter what we are machining, however, we cannot overlook the importance of using good quality tool holders. Milling chucks, high precision collet chucks and shrink fit holders will help ensure consistent tool life, surface finish quality, tolerance, and overall throughput. Establishing a preventive maintenance program to ensure that your holders are properly cleaned and well maintained will have a positive impact on your bottom line.

Machining aluminum presents its own unique set of challenges for all manufactures. Most industry segments including Aerospace, Automotive, Medical and General Machining manufacture components made from this “easy” yet sticky and gummy material. With the unique features of the newly upgrade A245/A345 such as the polished K-land, ANF PVD coating and the Cylindrical Margin, from Niagara Cutter, you can reduce the common problems associated with aluminum machining and improve your future applications.

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