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Key issues when milling aluminum alloy

Question

What are the key issues when milling aluminum alloy?

[Example work material]
A2017, A5052, A6061, A7075

Answer

Properties of aluminum alloy

Aluminum alloy is generally soft and therefore has good machinability, but due to its characteristics of having a low material melting point and a high level of ductility it has the disadvantage of being prone to adhering to the finish and the tool, and burrs occur easily.
High silicon aluminum alloy is a difficult-to-cut material because the contained crystalline silicon accelerates progressive tool wear, and various measures must be taken to address this when cutting the material.

■ Material hardness: the higher the value, the harder the material
■ Thermal conductivity: the higher the value, the higher the thermal conductivity
■ Work hardenability: the higher the value, the more easily the material is hardened
■ Ductility: the higher the value, the more ductile the material
■ Abrasive particle content: the higher the value, the more rapid the tool wears

Key issues when selecting tools

Tools that have a sharp cutting edge with a positive rake angle and a spacious area for cutting chip discharge are suited to this material.
The use of cutters with a negative rake angle results in considerable adhesion to the cutting edge, making milling difficult, as well as problems such as the deterioration of surface smoothness caused by built-up edges and failure to obtain required milling accuracy.
Select a tool that minimizes cutting temperature and has a smoother rake surface to ensure that cutting chips are ejected smoothly. Tools with diamond or DLC coatings have a low coefficient of friction and reduces the likelihood of adhesion, which are very effective.

Key issues when selecting a machining method

The basic approach to cutting aluminum alloy is to use a high cutting speed, and coolants are sometimes used to cool the cutting edge. Depending on the type of coolant used, a chemical reaction may occur between the coolant and the aluminum alloy and lead to changes in the composition of the workpiece surface, so care should be taken when selecting a coolant. Under suitable cutting conditions, tools with DLC coatings enables machining with an air blower instead of coolant, which is also environmentally friendly.
When cutting high silicon aluminum alloy, take cutting conditions of tool wear into account. For example, when roughing, using high-speed cutting is an effective approach.