Frequently Asked Question

High Speed milling of Aluminium
Last Updated 7 years ago

Aluminium is a prime candidate to be machined at high surface speeds. Typically, bonding materials in carbide tools such as Cobalt, can withstand temperatures up to 850 to 1000 Celsius depending on the grain size and chemical compositions. However, Aluminium melts around 600 Celsius; hence tool wear is not a prime issue in machining Aluminium alloys. Aluminium can be machined as fast as the machine tool spindle can rotate as long as the spindle has enough power and dynamic stiffness to operate without chatter vibrations. Therefore, one needs to predict chatter stability lobes, or sweet spots as the operators call it, while avoiding the violation of power limit of the machine tool.

You need to know the Dynamic Characteristics of the machine tool at the tool tip which can be measured using any Fourier Analyzer or CUTPRO MALTF module. The second important parameter is the material data, and CUTPRO has extensive material library including Aluminium alloys. The rest of the data is trivial such as approximate dimensions and angles of the tool, radial immersion conditions. If the part is flexible, you can include its dynamic measurements as well to CUTPRO. Milling Module of the CUTPRO predicts chatter stability lobes most accurately, and you can select a certain depth of cut under the lobe which does not lead to chatter, and feed rate. Milling module predicts everything about the process at this operating point, including forces, torque, power, vibrations at the tool tip, dimensional surface errors, chip thickness history, animation of the tool and surface motion.

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