If you want to drill holes with a particularly large diameter (i.e. greater than 10 mm) in wood – which are also called blind holes – it’s best to use a Forstner bit. However, this is not suitable for particularly deep holes or through holes.

I think you’re both right. you get more lifting force with a shallower incline, because of mechanical advantage, but it’s slower. Think of distance travelled along the Z axis per revolution.

There are a few coating options available for Aluminum tooling, including the popular gold-colored ZrN (Zirconium Nitride) and the lesser known but highly effective TiB2 (Titanium Diboride). Uncoated tooling can also provide solid machining performance. However, the real key to high performance machining in Aluminum is knowing the proper flute count and helix angle required for your operation.

You can also determine the size of the drill bit based on the screws you want to use. The diameter of the hole you drill should be slightly smaller than the diameter of the screw. So, for example, if you’re using a 3.5 mm screw, use a drill bit with a diameter of 3 mm.

Deep holes are similar to blind holes, except here the holes are particularly deep (at least five times deeper than the drill diameter). It’s the most common type of drilling if you want to mount something on the ceiling or wall. To give an example, you’ll need to drill deep holes to create your own vertical garden so that you can hang your project on the wall.

Lathecutting speedformula

In my experience, roughing style corncob type endmills will get you the highest MMR’s with your available hp at the spindle. I’ve been machining a job constantly on the search for a better roughing tool to increase the MMR. I’ve found HEM’s efficiency is entirely dependent on the part geometry that you are applying the toolpaths too. If your part dictates that there are substantial retracts/entries/exits from cutting, you may find that your sexy super fast feed rates end up with longer cycle times as you spend more time cutting air. I’ve spend countless hours on this, and even with the roughing tool I’m currently having major success with, it’s taken time to dial in the most efficient Spindle speeds and feeds. It’s not just about firing up the machine to the highest RPM and having at it. You need to find the sweet spot in the spindles torque curve. Once you’ve found where that is, then you can start jacking up feed rates and playing with axial and radial DOC’s

If your walls are made from perforated brick (similar to solid brick, but with evenly spaced cavities), you should try to use anchors that bridge the cavities or fill them in. Anchors with grout are ideal, as are plastic anchors that expand.

Is there an easy way to estimate the axial pull force created during HEM type roughing operations? I know this force can be quite high, often enough to merit the use of high grip tooling such as heat shrink or hydraulic holders. I’d be curious to hear some numbers, just to get a perspective on the forces involved and the necessary workholding requirements. For the sake of example, let’s say 6061 aluminum, 1/2″ 3 flute 45 deg. helix & 1500sfm.

Aluminum is available in two basic forms: Cast and Wrought. Wrought Aluminum is typically stronger, more expensive, and contains a lower percentage of outside elements in its alloys. Wrought Aluminum is also more heat-resistant than Cast and has a higher level of machinability.

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I have a requirement from my customer that the swarf be less than 0.5 mm on my supplied components. What is the standard for measuring swarf?

One of the most important things to consider when machining aluminum (and many other materials) is effective chip evacuation. Standard 2-3 flute end mills running at recommended speeds and feeds and proper chip loads can evacuate chips fairly well. However, 3 flute chipbreaker tooling can run at increased speed and feed rates for even better performance. The unique offset chip breaker geometry creates smaller chips for optimal evacuation while still leaving a semi-finished surface.

Finally, to provide more clarity on your point that chips must be lifted up through the flutes to be evacuated, this is correct for drills as there is nowhere else for the chips to go. For end mills, especially in low radial engagement situations such as with HEM, chips are ejected radially and are not really getting the chance to move up through the flutes. That small amount of vertical motion will actually be more with a higher helix.

The type of drill you need depends on several factors: the type of material you’re drilling, the type of hole you want to make, and the size of the hole (depth and diameter).

At its core, HEM is a roughing technique that utilizes a low Radial Depth of Cut (RDOC) and a high Axial Depth of Cut (ADOC) to take full advantage of the cutting edge of the tool. To learn more about how High Efficiency Milling can increase your efficiency, extend your tool life to keep costs down, and get greater performance for aluminum (and other materials), click here to download the HEM Guidebook.

If you need to drill all the way through a material, you need to make a through hole – a good example of this is our hanging lights project. If you’re making a through hole, the drill bit should be longer than the thickness of the material.

The size of the anchor you need will depend on the size of the hole you’re drilling. For example, if you used a 6 mm drill bit, you should use the same size anchor. The screws you use should then have a slightly smaller diameter of around 4–5 mm, which is opposite to if you're not using anchors (see 1.2). The wall anchor packaging will usually specify the length and diameter of the screws you should use.

Concrete is an ideal material for fixing or hanging items onto. Long wall anchors made from plastic and chemical solutions such as grout, with the right equipment, are especially suitable for this type of wall. For lightweight concrete, which is lighter than standard concrete thanks to the addition of Styropor or pumice, are ideal. These expand as the screw is tightened, ensuring they are firmly anchored in the wall.

While there are many factors that go into the parameters for every job, there are some general guidelines to follow when machining aluminum. For cast aluminum alloys (i.e. 308, 356, 380), a surface footage of 500-1000 SFM is recommended, with RPMs varying based on cutter diameter. The basic calculation to find a starting point for RPMs would be (3.82 x SFM) / Diameter.

A masonry or concrete drill bit is the preferred option for drilling very hard materials like concrete, natural stone or granite. It has a carbide tip and is usually made from tool/carbon steel.

If you're not using anchors, use the length and diameter of your screws to determine the drill bit length and the hole depth and diameter.

The article claims that a higher helix angle (45 degrees), makes for more aggressive cutting. If you look at the pictures you show of three endmills with 35, 40, and 45 degree helix’s, the one that would lift the chip further with each rotation of the cutter, is the tool with the 35 degree helix. So why wouldn’t that be considered a more aggressive attack on aluminum, and more suitable for high efficiency work?

Sometimes you don’t want to drill all the way through a material – for example, if you want to make invisible holes for hanging things up, as with our children's crown-shaped coat hook project. This is called a blind hole. It’s easy to make one in wood using a wood twist drill that is shorter than the thickness of the material. If you only have one drill bit that is longer than the material thickness, you can mark up the depth of the hole on the drill with tape. That way, you’ll know how far down to drill. If you need a drill with a bigger diameter, the Forstner bit is your best option.

Traditionally, 2 flute end mills have been the preferred choice for Aluminum. However, 3 flute end mills have proven to be more successful in many finishing operations, and with the right parameters they can also work successfully as roughers. While much of the debate between 2 and 3 flute end mills for Aluminum boils down to personal preference, the operation, rigidity, and desired material removal rates can also have an effect on tool selection.

To ensure pictures and shelves remain firmly on the wall, it’s important you use the right wall anchors. And the same rule applies as for drill bits: the anchor must be a good match for the material you’re drilling into.

The diameter of the drill bit you choose will depend on how big a hole you want to drill. Most drill bits nowadays have diameters of between 1 mm and 20 mm.

For the best results with drywalls, you should use either a drywall anchor or a special hollow wall anchor made from plastic and metal. This is suitable for use with cavities of different sizes and holds securely. A universal anchor is also an option, as it expands behind panels and cavities.

I’m not certain I agree with you. All other factors being equal (spindle speed, motor torque, feed rate and force, etc.), the low helix angle tool would seem to apply more force lifting the chip. (I’m thinking about vectors, but I’ve been out of school for 44 years, and was never good on this stuff.) I don’t have access to a CNC machine. So it’s not like I can run any tests.

If you’re telling me that an endmill with a high helix angle can be fed into the work faster because more cutting edges contact the work per revolution of the spindle, I would agree with you. But If I’m slotting or plunging, I want the chips out of the slot or hole, and I would think a low helix angle would accomplish that better.

Make sure you clean out the hole you've drilled before inserting the anchor. For example, you can use a handheld vacuum cleaner to remove any dust or remnants from drilling.

Generally speaking, drills can be divided up into metal drills, wood drills, masonry/concrete drills and multi-purpose ones. Most drill bits have a spiral shape – which helps to remove the drilled material from the hole.

High Efficiency Milling, commonly known as HEM, is a strategy that is rapidly gaining popularity in the manufacturing industry. Many CAM programs are now including HEM toolpaths, and while virtually any machine can perform HEM, the CNC controller must feature a fast processor to keep up with the additional lines of code. A great example of High Efficiency Milling toolpaths in Aluminum can be seen below.

Helical Solutions offers high balance tooling in standard 2 flute styles, as well as coolant-through 3 flute styles for reduced heat, enhanced chip evacuation, and increased material removal rates. These tools, like the chipbreakers, are also an excellent choice for High Efficiency Milling toolpaths.

Cutting speedchart for different materials

Aluminum is one of the most commonly machined materials, as most forms of the material feature excellent machinability, and is thus a commonly used material in manufacturing. Because of this, the competition for aluminum machining can be intense. Understanding the basics behind tool selection, running parameters, and advanced milling techniques for aluminum can help machinists earn a competitive advantage.

MultiConstruction drill bits can be used to drill into plastic and a range of other materials – making them ideal for drilling cabinet doors, for example, which consist not only of wood, but may also feature metal elements/fixtures. They are suitable for use on all materials that you’re likely to work on in the home, including multi-layer materials, bricks, tiles and aluminium. However, where possible, it’s always better to use the special drill bit for a specific type of material than the MultiConstruction bit – because these are developed especially for the material in question.

Cutting speedchart for turning

In wrought aluminum alloys (i.e. 2024, 6061, 7075), a surface footage of 800-1500 SFM is recommended, with the same calculation being used to find a starting point for RPMs.

For walls made from plasterboard, also known as drywall, you can use a special spiral-shaped drywall anchor made from metal or plastic. Unlike standard anchors, this does not expand. You should also use hollow wall anchors made from plastic or metal.

Cast Aluminum has less tensile strength but with a higher flexibility. It costs less, and has higher percentages of outside elements (silicon, magnesium, etc.) in its alloys, making it more abrasive than Wrought.

When machining aluminum, standard 2 or 3 flute tools will often get the job done. However, for certain applications and machine setups there are some more tooling options to consider for even better performance.

To prevent the tip of the drill from wearing out (drilling at too high a speed or with too much pressure may cause it to turn blue), try using drilling fluid or cutting oil. You could also remove the drill from the hole at regular intervals, to allow it to cool down slightly.

Cutting speedformula

Aluminum is a highly formable, workable, lightweight material. Parts made from this material can be found in nearly every industry. Additionally, Aluminum has become a popular choice for prototypes due to its low-cost and flexibility.

What makes a wood drill bit so different from a masonry bit? And why is it so important to use the right type of wall anchors? We’ve put together some tips on choosing the best drill bits and anchors for any task – so you can avoid breaking any more drills and can make sure your shelves stay firmly on the wall.

In general, a screw should always be slightly longer than the anchor to ensure it protrudes out from the wall. The longer an anchor is, the greater the load it can bear. So, the higher the load, the longer a screw should be in comparison to the anchor. Depending on the load, the screw can be between 3 mm (low load) and 16 mm (high load) longer.

Whether you’re drilling iron, steel, copper, brass or aluminium, it’s best to use a drill bit designed especially for metal. These are usually made from high-speed steel (HSS) and are cone-shaped at the top.

Lathecutting speedchart PDF

We thought you raised a great point about the high helix angle and how it wraps around the tool faster, making for an aggressive cut, and we agree that this could be misleading. We’ll rework this portion to provide more clarity. What we meant was that there are merits to using a high helix tool in an HEM fashion, since a higher helix causes more points of contact between the tool and the workpiece. This helps to provide stability to cut faster, and even provide more stability in thin wall applications. When we say “aggressive,” we’re referring more the nature of a high helix and less its use in HEM, specifically. A higher helix is more aggressive than a lower helix due to higher shear forces on the workpiece, and higher lifting forces, which can get too high in certain workholding situations.

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You can use a step drill bit to quickly and precisely drill holes in non-ferrous metals, sheet steel and plastics. Thanks to the different diameters on the bit, you can drill holes ranging from 4–20 mm. A centring aid helps you to drill accurately.

When it comes to a lower helix removing chips faster, we tend to disagree. As a helix becomes shallower, the vertical forces on each chip become less and are therefore unable to lift chips as quickly. As a helix becomes less and less, there is less lifting force on the chips and they are moved vertically at a far slower rate. A higher helix will actually lift chips more than a lower helix.

The helix angle of a tool is measured by the angle formed between the centerline of the tool and a straight line tangent along the cutting edge. Cutting tools for aluminum typically feature higher helix angles than standard end mills. Specialized helix angles for Aluminum are typically either 35°, 40°, or 45°. Variable helix tools are also available and make a great choice for reducing chatter and harmonics while also increasing material removal rates.

Metal lathecutting speedchart

End mills for aluminum are often available in either 2 flute or 3 flute styles. With higher flute counts, it would become difficult to evacuate chips effectively at the high speeds at which you can run in aluminum. This is because aluminum alloys leave a large chip, and chip valleys become smaller with each additional flute on an end mill.

High balance end mills are designed to significantly increase performance in highly balanced machining centers capable of elevated RPMs and feed rates. These tools are precision balanced specifically for high velocity machining in aluminum (up to 33,000 RPM).

Aluminum millingspeedchart

Sometimes you need to drill special types of holes or drill into unusual materials. Whatever your need, there’s a drill bit for the occasion.

A helix angle of 35° or 40° is a good choice for traditional roughing and slotting applications. A 45° helix angle is the preferred choice for finishing, but also for High Efficiency Milling toolpaths as the high helix angle wraps around the tool faster and makes for a more aggressive cut.

For drilling soft to medium-density tiles, you can use a special tile drill bit with a diamond-ground carbide tip. To prevent the drill from slipping off the surface, try sticking some tape to the tiles first and then drilling the hole. Some advice: start on a low speed setting and then gradually increase it as the drill bores deeper into the material. To avoid cracking your tiles, it’s important to apply the right amount of pressure. Apply moderate pressure to begin drilling the hole, then light to very light pressure as you proceed.

The different types of drill chucks include a self-centring/three-jaw chuck, which holds the drill bit in place with three "jaws" (points of attachment). By turning the chuck, it can be adapted to the diameter of the drill shank to firmly secure the bit. There are also various SDS chucks: here the drill bit snaps into place when it's inserted into the chuck, with no need to tighten the chuck or size it to the diameter of the drill shank.

Setting the right parameters for aluminum applications is vital to optimizing productivity and achieving better machining results. Since aluminum is an easier material to machine, pushing your machine to its limits and getting the most out of your tool is vital to stay ahead of the competition and keep winning business.

Cutting speedChart for milling

Soft or hardwood, chipboard, plywood or MDF panels – for all these types of wood, you’re best off using a wood twist drill bit. This has a centring point that enables you to position the drill precisely. Furthermore, tapered drill bits help to avoid ripping up the wood.

Not sure how deep to drill into a wall? Then base the depth on the wall anchors you want to use. As a rule of thumb, use the following formula to determine the depth of the hole: anchor length + 10 mm. This will ensure the anchor is completely out of sight later on.

When you go to the DIY store, you need to know which material you’re drilling, and what diameter and length drill you need: an image like the one above shows you what you can use the drill for. The diameter of the bit can usually be found in a box in the top-left corner, whilst the total and working length can be seen on the tape measure along the edge of the packaging.

Aluminum is a versatile material with a high level of machinability, but it should not be overlooked. Understanding the best ways to tackle it is important for achieving the desired results. Optimizing your tool crib, machine setups, and toolpaths for aluminum is essential to stay ahead of the competition and make your shop more efficient.

In addition to the various tips, drill bits also differ in terms of their shank shape. The shank is the part that is inserted into the drill chuck.

These tools are excellent for more advanced toolpaths like High Efficiency Milling, which is another important tool for a successful aluminum machining experience.

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Thanks for the question! This would depend on the material grade, speeds and feeds, coolant used, etc., so it’s tough to give one exact temperature. However, the Helical Solutions Zplus coating is great in aluminum and can handle up to 1,110° F. Please give us a call at 866-543-5422 for more information, and one of our tech representatives can learn more about your application!

Unfortunately, there is no easy way to calculate the axial pull force on a tool during HEM roughing applications. We are currently working on a way to calculate this but there are a lot of different variables that go into this. If you are worried about any application you may be performing and a possible tool pull out, I am more than happy to get you in touch with one of our application engineers who have had countless years of experience and will be able to tell you if you will have any issues.