Machining Aluminum Generally highest cutting speed allowable ¢ Excellent machined surface finish Low cutting force Good dimensional control Outstanding tool life Juminum Machinability ratings are based on chipping characteristics: % A-Rated: Very small chips, excellent surface finish Alloys 2011, 6020 % B-Rated: —_Curled or easily broken chips, Good to excellent finish Alloys 2024, 2017, 6262, 6013, 4032, 7075 % C-Rated: Continuous chips, good surface finish Alloys 6061, 6005 % D-Rated: Continuous chips, satisfactory finish Alloys 6063, 5056 Note: tooling can range from high speed steel to carbide inserts and even coated carbide, depending on the alloy being machined. Diamond tooling is used for best surface finish. MACHININGAluminum Alloy Selection 2011 Alloy -T3, -T451, -T8 Tempers ~-Free machining (Pb + Bi addition) ~Readily available ~-Poor anodizing response ~Poor corrosion resistance ~-Cold finished only 6262 Alloy -T6, -T651, -T6511, -T8, -T9 Tempers ~Intermediate machinability (Pb + Bi addition) ~-Better corrosion resistance and anodizing response than 2011/2024 alloys ~-Available in cold-finished and extruded product Aluminum Alloy Selection 2024 Alloy -1351, -T4, -T6, -T851 Tempers ~-Excellent deep drilling characteristics ~-Improved SCC resistance in T8/T851 tempers ~-Available in cold-finished and extruded lloy -16, -T6511, -T73, -T7351 Tempers High strength alloy ~Chipping not as good as 2024 and 6262 --Corrosion resistance/anodizing response not as good as 6262 6061/6082 Alloy -T6, -T6511 Tempers Moderate machinabi --Chipping not as good as 6262 Alloy Most recognized alloy by designers Good corrosion/anodizing response 7075 MACHININGchining Aluminum Tooling Recommendations + Tools and tool holders must be rigid. Tools should have a finely ground edge to mini + Cutting edges should be kept sharp at all times. Chips must be directed away from the work piece or broken up by a chip breaker to prevent part damage. Increase productivity by increasing speeds while maintaining feed rates and using moderate depth of cuts. Avoid using excessive cutting pressures unless the workplace is, adequately supported. 4 Use lower feed rates on thin walled parts. Use recommended rake angles to reduce cutting forces - this produces thinner chips and reduces metal buildup. ¥ Use coolant feed drills, high pressure coolant feed systems. ze buildup. Deburring Methods/Technique: + Thermal Deburring - Thermal Energy Method (TEM) Vaporizes internal external burrs with intense heat + Vibratory / Tumble Deburring Abrasive media used to knock off burrs + High Pressure Deburring Cutting oil, water, abrasive medium used to erode protruding burrs + Mechanical Deburring - Manual tools to physically cut, grind, sand burrs - Automated methods to remove burrs as part of machining process or secondary operation. + Chemical Deburring to dissolve material MACHINING.achining Aluminum Drilling Suggestions Helix Angle - High Helix angle - 40 to 50° deep hole drilling ~ General purpose drils = 25 to 30° Flutes - Highly polished to minimize chip packing & buildup = Parabolic = Symmetrical flutes to minimize chip packing Point Angle ~ 118 degrees OK for shallow holes = Deep hole drilling - 130 to 140" narrower chip readily clears the hole Feed Rates See following table Machining Aluminum Turning Tool Suggestions Top Rake Angle Less positive for free cutting alloys 0 to 5 degrees for 2011, 6020, and 6262 More positive for B and C-Rated materials 5 to 10 degrees for 2024, 7075, 6061, 6082 ‘Tool wear can increase with more positive angle. Feed Rates Alloy dependent See following table. MACHININGMachining Feeds & S| ‘Suggested Practices for Turning Aluminum ‘on General-Purpose Equipment" (001300 ‘ie fo 080 Up 1000 tom 1p to 15000 fom (Gepending on the nts ef the port MACHININGMACHININGilling Aluminum 1 is very suitable for aluminum alloys using a rotating tool that ‘continuously brings fresh edges into action. Each tooth produces a short chip to improve effectiveness of the cutting fluid, ‘Aluminum can be easily milled at high speeds. ‘Machine rigidity is important to prevent chatter. Milling is often performed as climb cutting (both work & cutter teeth move in the same direction). ‘The cutter must be highly polished cutters with coarse-pitch teeth and large flutes are recommended. Machinery available include: horizontal milling, vertical milling, universal milling and routing. ‘Milling is generally performed on CNC machining centers using a cutting Milling ise ing, * Drills for machining aluminum typically have large helix angles & large, polished flutes for rapid chip removal & to prevent uild-up. * Standard drills, (for drilling steel), can be used effectively to = Drilling operations are general + Holes drilled in aluminum may become oversized. In soft alloys drill shallow holes. Special drills are available specifically for aluminum. performed with a cutting fluid. the diameter may be slightly larger than the drill. If close diameter tolerances are required, it is recommended to use a smaller drill then reamed to the desired size. MACHININGFeed Rates for Drilling Aluminum Feed, IPR Alloys Alloys Hote ro 6260, 600, 061.2075 2011 2024 Coen 6082 V8 in. pole O10 a 1/4 in, tee ond naa 3/8 in, aan on ora Win, 0204 017 010 on 0204 017 O11 5/8 in, 0204 017 pu 3/4 in, 0204 017 a (D COGN is an Alcoa designation for a low lead 6x alloy 10 comply with ROHS Turning Aluminum + Turning aluminum alloys should be carried out at high speeds and with cutting fluids to cool the work piece and prevent build up on the tooling. * Work piece must be properly clamped to avoid surface damage. * Multiple jaw chucks, ex) 3, 4, 6, are available for good clamping with low pressure. + Thermal expansion of aluminum may occur which needs to be considered when fixturing. Hollow parts held by outward pressure may loosen due to thermal expansion. MACHININGFeed Rates, IPR Alloys Alloys Alloys 6262, 2024 7075, 6061 Width of tool* 2011, 6020 ‘COGN 6082 U8- U4 005 004 0025 0035, 003 002, 38 - 1/2 in. 004 004 002 003 0025 0015 5/8 - 3/4 in. 0035 .003 .0012 0025 0015 0010 lin, .003 0025 .0005-.0010 0015 .0008-.0012 _ *Top value refers to form tooling performed with no additional simultaneous operations Bottom value refers to form tooling performed with other operations simultaneously ()COBN is an Alcoa designation for alow lead 6x alloy to comply with ROHS & ELV. Reaming Aluminum = Standard reamers and special reamers with large highly polished flutes can be used on aluminum. = Spiral flutes cause less chatter and improved surface finish vs. straight flutes. Hand-fed reamers should use a negative spiral to minimize self-feeding of the tool into the hole. Counterboring Aluminum * Counterboring aluminum can be performed with standard tools (three or more teeth according to diameter). = Counterboring (countersinking) is often used to deburr drilled holes or form seats for O-ring seals. = Generally necessary to use a cutting fluid. Cutting fluids should be used for reaming and counter boring. MACHININGThreading, Tapping, Thread Rolling ‘= Threading Special dies are used threads. proper rake and chamfer angles for cutting external * Cutting fuids recommended with threading + Tapping * When tapping higher strength alloys, standard taps (use for stel or brass) are acceptable but special aps designed for aluminum provide improved results. + Taps for aluminum should have deep, wide well polished flutes. irl-luted taps are often used for blind holes. flutes are often used for through-holes. * Cutting fuids ae recommended for tapping * Thread rolling (roll forming material to create threads) * Faster method of creating threads than tapping and threading * Rolled threads are stronger & have improved fatigue resistance than cut threads * Improved resistance to abrasion and binding in service. * The equipment methods used for thread rolling aluminum ae similar to those used for ste! or brass. Special tooling design for aluminum may need to be considered. Machining Lubricants Mineral Oils - Fatty additive type preferred for aluminum Emulsions - 3 to 5% soluble oil in coater, for aluminum - Multipurpose, chlorinated extreme-pressure oil with anti-stick slip additives Aqueous Chemical Solutions ‘Tables on Lubricants 10 MACHININGCutting fluids Cutting fluids are used for both cooling and lubrication. Different machining methods can require different types of cutting fluids. Cutting fuid ty, 1. Aqueous emulsion of mineral oil 2.0. Mineral, tard or essential oil. + 3. Compound oil - mineral oil and lard or essential ol 1 4 Aqueous chemical solutions + 5. Paraffin or alcohol #6 Wax ora mixture of wax & grease (allow). Cemented Carbide Grade Comparison Chart for Aluminum ‘CODE ‘Chip Removal Applications ct Roughing cuts e General purpose c Light finishing cs Precision boring Advances in Tool Coatings AL-TI-N ~ Banit Futura & Extreme Series 210 3x increas in ol life fr drils Silver Coatings: ~Titankote + C3 “Lower coefficient of fiction = Drills, taps & broaching tools MACHININGCEMENTED CARBIDE GRADE COMPARISON CHART FOR ALUMINUM eae Cpa a gE Regs. is eens ge enc-uaee g aetie te ce ca & ieee. Taourayl = cr jew [ena fas [wm [ms [aun [eume |vosnoa] ver lasue | | = ce fon fa fore fomtm [rae faa.nac fae foo | vor fas | ot | me & leo ies leo ies ko ip en vor fer || vor | os pennfarriicrrions Hb-20 23 | HBB | al wba | ‘The above chart liste the standard grades of carbides and the recommended srade for specific application, ‘The chart is not a grade comparison hart, nor isi endorsement of any manufacturers product. The information Tsted herewith ig approximate and insttions regarding the specific uze and application of any competitive rade should be obtained direct Irom the manufacturer, MACHINING 12