I was wrong about using a 3/8 end mill for that aluminum job

Had to make a bunch of slots in 6061, and I was set on using a 3/8 tool for speed. My boss told me to try a 1/2 inch with a lower feed rate instead. I ran it his way on the Haas last Thursday, and the finish was way smoother with no chatter. The bigger tool just handled the cut better. Anyone have a go-to end mill size for aluminum slotting?

3 comments

3 Comments

evan29521d ago

Had a job cutting pockets in some 6061 plates last month. I was using a 1/4 inch end mill and it just felt weak, lots of vibration. Switched to a 3/8 like you tried, and it was okay. But then I grabbed a 1/2 inch four-flute from the cabinet, dropped the feed a bit, and it was night and day. The part finish looked clean and the machine just sounded happier, no more of that screechy noise.

veramiller1d ago

Did you check if that 3/8 tool was sharp or maybe a little worn out?

williams9021d ago

Honestly, is the finish difference that big of a deal? A 3/8 tool gets the job done. It's just aluminum, not some crazy alloy. Sometimes you just use what's already in the machine to save time. If the part passes inspection, who cares if it could be a little shinier? Bosses always want to overthink the simple stuff.

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