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Aluminum 6061-T6

Excellent machinability

The most versatile and widely used aluminum alloy (40 ksi yield strength, 95% machinability rating), offering excellent machinability, good strength-to-weight ratio, and corrosion resistance. T6 temper provides optimal balance of strength and workability for aerospace, automotive, and general machining applications.

Surface speed
800-1500 SFM (244-457 m/min)
Feed rate
0.004-0.012 IPR (0.1-0.3 mm/rev)
Depth of cut
Up to 3x tool diameter for roughing

Starting points only. Adjust for your machine rigidity, tool maker data, and setup.

Tooling

Recommended
2-3 flute carbide end mills, Polished flute tools, High helix angles (45°+)
Coatings
Uncoated carbide preferred, ZrN for extended life, DLC for mirror finishes
Geometry
Sharp cutting edges, high positive rake angles (15-20°), large chip gullets for evacuation

Coolant

Type
Flood coolant or mist
Concentration
6-8% water-soluble oil
Delivery
High volume, low pressure to clear chips

Common applications

Aerospace structural componentsAutomotive parts and bracketsMarine hardwareElectronic enclosuresJigs and fixturesBicycle frames and componentsDrone and UAV frames

Tips

  • Use highest spindle speeds available - aluminum loves speed
  • Prioritize chip evacuation over cooling; aluminum dissipates heat well
  • Apply climb milling for better surface finish and reduced tool deflection
  • For deep pockets, use 2-3 flute tools with polished flutes to prevent chip packing
  • Pre-heat material to 150°F for reduced built-up edge on finishing passes
  • Consider through-spindle coolant for deep hole drilling

Warnings

  • Avoid excessive dwelling - causes work hardening and built-up edge
  • Never use titanium-coated tools - aluminum sticks to TiN/TiAlN
  • Thin walls require reduced feed rates to prevent vibration
  • Watch for chip welding at low speeds or insufficient coolant

Troubleshooting

Built-up edge on cutting tool
Cause: Speed too low, insufficient coolant, or dull tool
Fix: Increase spindle speed by 20%, ensure adequate coolant flow, replace worn tools
Poor surface finish with visible tool marks
Cause: Feed rate too high or chip re-cutting
Fix: Reduce feed rate, improve chip evacuation, use climb milling
Chips welding to workpiece
Cause: Insufficient chip clearance or wrong coolant type
Fix: Switch to air blast or mist coolant, use polished flute tools