Problems with soft aluminum

[FinnCNC]

Hi!

I have huge problem with milling soft aluminum. Im not sure what alloy it is exactly but it is very soft and gummy. Guy who sold this material told that it is grade that is not supposed to be machined.

Current cutting parametres:
Feed: 3000m/min
RPM: 12000rpm
DOC: 2mm
Passes: 3

I need to cut several hundreds pieces made from this stuff. Im using GARR 2-flute 10mm solid carbide endmill and flood coolant. 2mm DOC is absolute max with this setup. Any deeper and aluminum just melts rather than cuts. It takes ages with 2mm DOC. With harder alloys i can easily get 6mm DOC per pass or even more. Coolant spray is pointed right where carbide meets aluminum.

Is there some way (maybe other type endmill) to make deeper cuts?

[Geof]

Are you using the high helix two flute cutters from GARR? I think the code is 242M, they have a 45degree helix. We machine a T0 aluminum alloy and find these are the best cutter for clearing the chip out.

I had described our conditions in this thread:

http://www.cnczone.com/forums/showthread.php?t=60698

I would also use a larger diameter cutter if possible, something like 15mm to give more room for chips.

[lin_chihchan]

don't know the outer dia. you talking about. for alu, can use indexable cutter, only changing carbide inserts. give u a website to look at.
www.cutting-tools.com.tw