How to millaluminumat home

As a result, your sweet spot will be pretty narrow, depending on the type of work (roughing, finishing, etc.), the cutter diameter, and the aluminum grade. Check with a feeds and speeds calculator or your tooling manufacturer’s charts.

CNCmillingmachine

We say it again: cutting aluminum generates a lot of heat. You’ve got to keep things cool to prevent material softening, tool wear, poor surface finish, and other issues.

It’s very ductile stuff, meaning that it tends to stretch when cut (instead of just breaking into small bits). But, the key material property to remember about aluminum is that it has a very low melting point, and when it does melt, it sticks to the cutting edge of your tooling.

Also, pay attention to the size of your chips. This is largely determined by your speeds and feeds. You want to see thinner chips that don’t look like shavings. Take this information and fine fine-tune your speeds and feeds off of it.

Aluminum millingmachine

American Rotary’s rotary phase converters are a smart solution. One of our USA-built units can provide your shop with 3-phase power at a fraction of the cost of running a 3-phase line to your location and more efficiently than using other types of phase converters.

Cutting aluminum also creates long chips, so you want tooling that supports good chip clearance. Choose tools with a maximum of three flutes.

Milling aluminumwith a router

In any case, keep checking those chips to make sure they’re getting cleared out. Meanwhile, note the color of the chips, which may indicate various problems:

Because of aluminum’s high thermal conductivity and low melt point, you need to manage several tricky issues when machining this popular material to avoid tool damage and other frustrations. Fortunately, you can follow these 5 tips for aluminum machining to maximize efficiency.

Be sure to keep clearing your chips. That 3-flute maximum on the cutter will help with chip removal. So will using a cutting fluid to help flush away chips. Or consider an air blasting system to keep things clean.

Depending on your machining operation, you can use flood cooling—continuously applying the coolant—or intermittent mist cooling.

One more thing about machining aluminum: the high-quality milling machine you use is likely to need 3-phase electricity. So what do you do if your machine shop has the typical residential single-phase power service?

Millaluminumfinish

Aluminum millingServices

To prevent these issues, you need carbide-cutting tools that can handle high RPMs while maintaining a sharp edge to keep cutting right through the metal.

Don’t try to make deeper cuts to save some time, as this will cause tool deflection and tool breakage. Instead, doing more shallow passes will enable better chip clearance.

Millingaluminium speeds and feeds

In a conventional milling operation, high spindle speeds are advised. As for feed rate, low FPM rates can create friction that harms your tools. Conversely, fast feeds can put too much stress on your equipment.

Considering that aluminum can melt during cutting and cause broken tools, set your machining speeds and feeds carefully.

Aluminummachining near me

In addition, apply a coolant cutting fluid to the tool and the workpiece. The coolant will help dissipate heat, reduce friction, and improve chip evacuation.

Those long chips created by cutting aluminum? They can build up around your tooling and cause all kinds of problems: sticky buildup, increasing heat, and more.

Machining aluminum may be less straightforward than steel, but it’s within your grasp if you do your due diligence. Just take your time and keep all these tips in mind. And don’t hesitate to consult experienced experts if you have any questions or concerns.

The drill bit size chart provides equivalent sizes for letter, metric, wire gauge, and fractional drill bit sizes, allowing the user to select the correct drill bit for their project.

Aluminum is a soft and ductile metal used in a wide range of applications. Should be easier to machine than harder materials, right? Not so fast, my machinist friend.

Drill Bit Size Chart Drill Size Diameter (inches) Diameter (mm)   Drill Size   Diameter (inches)  Diameter (mm)    Drill Size   Diameter (inches)  Diameter (mm) #107 0.0019 0.0483   #26 0.147 3.7338   X  0.397 10.0838 0.05 mm 0.002 0.05   #25 0.1495 3.7973   Y 0.404 10.2616 #106 0.0023 0.0584   3.8 mm 0.1496 3.8   13/32 in 0.4063 10.3188 #105 0.0027 0.0686   #24 0.152 3.8608   Z 0.413 10.4902 #104 0.0031 0.0787   3.9 mm 0.1535 3.9   10.5 mm 0.4134 10.5 #103 0.0035 0.0889   #23 0.154 3.9116   27/64 in 0.4219 10.7156 #102 0.0039 0.0991   5/32 in 0.1563 3.9688   11 mm 0.4331 11 0.1 mm 0.0039 0.0991   #22 0.157 3.9878   7/16 in 0.4375 11.1125 #101 0.0043 0.1092   4 mm 0.1575 4   11.5 mm 0.4528 11.5 #100 0.0047 0.1194   #21 0.159 4.0386   29/64 in 0.4531 11.5094 #99 0.0051 0.1295   #20 0.161 4.0894   15/32 in 0.4688 11.9063 #98 0.0055 0.1397   4.1 mm 0.1614 4.1   12 mm 0.4724 12 #97 0.0059 0.1499   4.2 mm 0.1654 4.2   31/64 in 0.4844 12.3031 #96 0.0063 0.16   #19 0.166 4.2164   12.5 mm 0.4921 12.5 #95 0.0067 0.1702   4.3 mm 0.1693 4.3   1/2 in 0.5 12.7 #94 0.0071 0.1803   #18 0.1695 4.3053   13 mm 0.5118 13 #93 0.0075 0.1905   11/64 in 0.1719 4.3656   33/64 in 0.5156 13.0969 0.2 mm 0.0079 0.2   #17 0.173 4.3942   17/32 in 0.5313 13.4938 #92 0.0079 0.2007   4.4 mm 0.1732 4.4   13.5 mm 0.5315 13.5 #91 0.0083 0.2108   #16 0.177 4.4958   35/64 in 0.5469 13.8906 #90 0.0087 0.221   4.5 mm 0.1772 4.5   14 mm 0.5512  14 #89 0.0091 0.2311   #15 0.18 4.572   9/16 in 0.5625 14.2875 #88 0.0095 0.2413   4.6 mm 0.1811 4.6   14.5 mm 0.5709 14.5 #87 0.01 0.254   #14 0.182 4.6228   37/64 in 0.5781 14.6844 #86 0.0105 0.2667   #13 0.185 4.699   15 mm 0.5906 15 #85 0.011 0.2794   4.7 mm 0.185 4.7   19/32 in 0.5938 15.0813 #84 0.0115 0.2921   3/16 in 0.1875 4.7625   39/64 in 0.6094 15.4781 0.3 mm 0.0118 0.3   4.8 mm 0.189 4.8   15.5 mm 0.6102 15.5 #83 0.012 0.3048   #12 0.189 4.8006   5/8 in 0.625 15.875 #82 0.0125 0.3175   #11 0.191 4.8514   16 mm 0.6299 16 #81 0.013 0.3302   4.9 mm 0.1929 4.9   41/64 in 0.6406 16.2719 #80 0.0135 0.3429   #10 0.1935 4.9149   16.5 mm 0.6496 16.5 #79 0.0145 0.368   #9 0.196 4.9784   17 mm 0.6693 17 1/64 in 0.0156 0.3969   5 mm 0.1969 5   43/64 in 0.6719 7.0656 0.4 mm 0.0158 0.4   #8 0.199 5.0546   11/16 in 0.6875 17.4625 #78 0.016 0.4064   5.1 mm 0.2008 5.1   17.5 mm 0.689 17.5 #77 0.018 0.4572   #7 0.201 5.1054   45/64 in 0.7031 17.8594 0.5 mm 0.0197 0.5   13/64 in 0.2031 5.1594   18 mm 0.7087 18 #76 0.02 0.508   #6 0.204 5.1816   23/32 in 0.7188 18.2563 #75 0.021 0.5334   5.2 mm 0.2047 5.2   18.5 mm 0.7284 18.5  #74 0.0225 0.5715   #5 0.2055 5.2197   47/64 in 0.7344 18.6531 0.6 mm 0.0236 0.6   5.3 mm 0.2087 5.3   19 mm 0.748 19 #73 0.024 0.6096   #4 0.209 5.3086   3/4 in 0.75 19.05 #72 0.025 0.635   5.4 mm 0.2126 5.4   49/64 in 0.7656 19.4469 #71 0.026 0.6604   #3 0.213 5.4102   19.5 mm 0.7677 19.5 0.7 mm 0.0276 0.7   5.5 mm 0.2165 5.5   25/32 in 0.7813 19.8438 #70 0.028 0.7112   7/32 in 0.2188 5.5563   20 mm 0.7874 20 #69 0.0292 0.7417   5.6 mm 0.2205 5.6   51/64 in 0.7969 20.2406 #68 0.031 0.7874   #2 0.221 5.6134   20.5 mm 0.8071 20.5 1/32 in 0.0313 0.7938   5.7 mm 0.2244 5.7   13/16 in 0.8125 20.6375 0.8mm 0.0315 0.8   #1 0.228 5.7912   21 mm 08268 21 #67 0.032 0.8128   5.8 mm 0.2284 5.8   53/64 in 0.8281 21.0344 #66 0.033 0.8382   5.9 mm 0.2323 5.9   27/32 in 0.8438 21.4313 #65 0.035 0.889   A 0.234 5.9436   21.5 mm 0.8465 21.5 0.9 mm 0.0354 0.9   15/64 in 0.2344 5.9531   55/64 in 0.8594 21.8281 #64 0.036 0.9144   6 mm 0.2362 6   22 mm 0.8661 22 #63 0.037 0.9398   B 0.238 6.0452   7/8 in 0.875 22.225 #62 0.038 0.9652   6.1 mm 0.2402 6.1   22.5 mm 0.8858 22.5 #61 0.039 0.9906   C 0.242 6.1468   57/64 in 0.8906 22.6219 1 mm 0.0394 1   6.2 mm 0.2441 6.2   23 mm 0.9055 23 #60 0.04 1.016   D 0.246 6.2484    29/32 in 0.9063 23.0188 #59 0.041 1.0414   6.3 mm 0.248 6.3   21/23 in 0.913 23.1913 #58 0.042 1.0668   1/4 in  0.25 6.35   59/64 in 0.9219 23.4156 #57 0.043 1.0922   E 0.25 6.35   23.5 mm 0.9252 23.5 1.1 mm 0.0433 1.1   6.4 mm 0.252 6.4   15/16 in 0.9375 23.8125 #56 0.0465 1.1811   6.5 mm 0.2559 6.5   24 mm 0.9449 24 3/64 in 0.0469 1.1906   F 0.257 6.5278   61/64 in 0.9531 24.2094 1.2 mm 0.0472 1.2   6.6 mm 0.2598 6.6   24.5 mm 0.9646 24.5 1.3 mm 0.0512 1.3   G 0.261 6.6294   31/32 in 0.9688 24.6063 #55 0.052 1.3208   6.7 mm 0.2638 6.7   25 mm 0.9843 25 #54 0.055 1.397   17/64 in 0.2656 6.7469   63/64 in 0.9844 25.0031 1.4 mm 0.0551 1.4   H 0.266 6.7564   1 in 1 25.4 1.5 mm 0.0591 1.5   6.8 mm 0.2677 6.8   25.5 mm 1.0039 25.5 #53 0.0595 1.5113   6.9 mm 0.2717 6.9   1-1/64 in 1.0156 25.7969 1/16 in 0.0625 1.5875   I 0.272 6.9088   26 mm 1.0236 26 1.6 mm 0.063 1.6   7 mm 0.2756 7   1-1/32 in 1.0313 26.1938 #52 0.0635 1.6129   J 0.277 7.0358   26.5 mm 1.0433 26.5 1.7 mm 0.0669 1.7   7.1 mm 0.2795 7.1   1-3/64 in 1.0469 26.5906 #51 0.067 1.7018   K 0.281 7.1374   1-1/16 in 1.0625 26.9875 #50 0.07 1.778   9/32 in 0.2813 7.1438   27 mm 1.063 27 1.8 mm 0.0709 1.8   7.2 mm 0.2835 7.2   1-5/64 in 1.0781 27.3844 #49 0.073 1.8542   7.3 mm 0.2874 7.3   27.5 mm 1.0827 27.5 1.9 mm 0.0748 1.9   L 0.29 7.366   1-3/32 in 1.0938 27.7813 #48 0.076 1.9304   7.4 mm 0.2913 7.4   28 mm 1.1024 28 5/64 in 0.0781 1.9844   M 0.295 7.493   1-7/64 in 1.1094 28.1781 #47 0.0785 1.9939   7.5 mm 0.2953 7.5   28.5 mm 1.1221 28.5 2 mm 0.0787 2   19/64 in 0.2969 7.5406   1-1/8 in 1.125 28.575 #46 0.081  2.0574   7.6 mm 0.2992 7.6   1-9/64 in 1.1406 28.9719 #45 0.082 2.0828   N 0.302 7.6708   29 mm 1.1417 29 2.1 mm 0.0827 2.1   7.7 mm 0.3032 7.7   1-5/32 in 1.1563 29.3688 #44 0.086 2.1844   7.8 mm 0.3071 7.8   29.5 mm 1.1614 29.5 2.2 mm 0.0866 2.2   7.9 mm 0.311 7.9   1-11/64 in 1.1719 29.7656 #43 0.089 2.2606   5/16 in 0.3125 7.9375   30 mm 1.1811 30 2.3 mm 0.0906 2.3   8 mm 0.315 8   1-3/16 in 1.1875 30.1625 #42 0.0935 2.3749   O  0.316 8.0264   30.5 mm 1.2008 30.5 3/32 in 0.0938 2.3813    8.1 mm  0.3189 8.1   1-13/64 in 1.2031 30.5594 2.4 mm 0.0945 2.4   8.2 mm  0.3228 8.2   1-7/32 in 1.2188  30.9563 #41 0.096 2.4384   P 0.323 8.2042   31 mm 1.2205 31 #40 0.098 2.4892   8.3 mm 0.3268 8.3   1-15/64 in 1.2344 31.3531 2.5 mm 0.0984 2.5    21/64 in 0.3281 8.3344   31.5 mm 1.2402  31.5 #39 0.0995 2.5273   8.4 mm 0.3307 8.4    1-1/4 in 1.25 31.75 #38 0.1015 2.5781   Q 0.332  8.4328   32 mm 1.2598 32 2.6 mm 0.1024 2.6   8.5 mm 0.3347 8.5   1-17/64 in 1.2656 32.1469 #37 0.104   2.6416   8.6 mm 0.3386 8.6   32.5 mm 1.2795 32.5 2.7 mm 0.1063  2.7   R 0.339 8.6106   1-9/32 in 1.2813 32.5438 #36 0.1065 2.7051   8.7 mm 0.3425 8.7   1-19/64 in 1.2969  32.9406 7/64 in 0.1094 2.7781   11/32 in 0.3438 8.7313   33 mm 1.2992 33 #35 0.11  2.794   8.8 mm 0.3465 8.8   1-5/16 in  1.3125  33.3375  2.8 mm 0.1102 2.8   S 0.348 8.8392   33.5 mm 1.3189 33.5 #34 0.111 2.8194   8.9 mm  0.3504  8.9   1-21/64 in 1.3281 33.7344 #33 0.113 2.8702   9  0.3543 9   34 mm 1.3386 34 2.9 mm 0.1142 2.9   T  0.358  9.0932   1-11/32 in 1.3438 34.1313 #32 0.116 2.9464    9.1 mm 0.3583 9.1   34.5 mm 1.3583 34.5 3 mm 0.1181  3   23/64 in 0.3594 9.1281   1-23/64 in 1.3594 34.5281 #31  0.12 3.048    9.2 mm 0.3622 9.2   1-3/8 in 1.375 34.925 3.1 mm 0.1221 3.1    9.3 mm 0.3661 9.3   35 mm 1.378 35 1/8 in 0.125 3.175   U 0.368 9.3472   1-25/64 in 1.3906 35.3219 3.2 mm 0.126  3.2   9.4 mm 0.3701 9.4   1-3/8 in 1.375 34.925 #30 0.1285 3.2639   9.5 mm  0.374 9.5   35 mm 1.378 35 3.3 mm 0.1299 3.3   3/8 in  0.375 9.525   1-25/64 in 1.3906 35.3219 3.4 mm 0.1339 3.4   V 0.377 9.5758   35.5 mm 1.3976 35.5 #29 0.136 3.4544   9.6 mm 0.378 9.6   1-13/32 in 1.4063 35.7188  3.5 mm 0.1378 3.5   9.7 mm 0.3819 9.7    36 mm 1.4173 36 #28 0.1405 3.5687   9.8 mm 0.3858 9.8   1-27/64 in 1.4219 36.1156 9/64 in 0.1406 3.5719   W 0.386   9.8044   36.5 mm 1.437 36.5 3.6 mm 0.1417  3.6    9.9 mm 0.3898 9.9   1-7/16 in 1.4375 36.5125 #27 0.144 3.6576    25/64 in  0.3906 9.9219   1-29/64 in 1.4531 36.9094 3.7 mm 0.1457  3.7    10 mm 0.3937 10   37 mm  1.4567 37 The drill bit size chart provides equivalent sizes for letter, metric, wire gauge, and fractional drill bit sizes, allowing the user to select the correct drill bit for their project.