30x30 LM, 1/4" carbide up cut endmill, Makita router. What would be a good starting point to cut aluminum (6061), speed and feeds?
First recommandation is to use a 1/8" bit made for cutting aluminium. Feeds and speeds should be provided by the manufacturer.
I also started cutting aluminium with random bits and the main results was pain in ears and eyes.
Unless you want to try the 1/4" bit, I suggest using same speeds and feeds as for wood but a really small cutting depth… 0.1mm to 0.5mm
1 Like
@ozguzzi Several users have had success milling aluminum. Here are the settings that I have used. I got them some time ago from @BillKorn
Using a single flute or o-flute bit, of nominal 1/8" diameter, I use about 0.015" DOC with about 20% stepover at 22 in/min.
This is very conservative, but gives a very good finish off the machine.
One final thing. Keep the router as high up in the clamp as you can. This reduces the lever effect on the Z gantry and improves accuracy.
1 Like
Thanks JHahn and gwilki. I am making a three wheeled motorcycle, and need some aluminum parts. Should prove to be interesting.
I did get the project done. Broke a couple of endmills (I expected that), but the parts turned out OK. Tried using lube, but had better luck running it dry. Thanks guys for the advice.
What bit did you use in the end? I’ve been using a 3tooth spiral cutter 4mm diameter. I’m going to try a smaller one as 4mm on 10mm ally plate is a lot of material to move. I typically use a 0.4mm cut depth at 800mm/min and 12000 rpm.
The best coolant I have found is Isopropyl Alcohol with an air spray head and a barely visible spray. The evaporation keeps the tool cool and seems to eliminate the tendency of chis binding to the teeth. As a bonus it makes no mess and doesn’t contaminate the swarf.