Milling aluminum cleanly

J

Jkassis

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It seems that unless I climb-cut my aluminum blocks, as in cutting a radius on the top of the block with a radius end mill cutter, I always get a bad finish. When I climb cut, it comes out nicely. The speed doesn't seem to matter. It's a new bit on a new Sharp LMV knee mill, so it shouldn't be the machine. Can anyone tell me what I am doing wrong? Bad bit? Wrong speed? :headscratch:
 
Climb cutting is generally the prefered direction we use, if your machine rigidity and operation allows for it. The chip actually thins on the exit of cut , which usually provides a better finish.

Cutting aluminum in any direction , likes to have good lubrication , try using a simple spray of WD40 or other light oil on your finish passes to reduce chips galling to the cutter. and should provide a decent finish.
 
Kerosene is also a good cutting fluid for aluminum. End mills with fast spirals and 2 flutes are the best for aluminum also.
 
Thanks so much everyone for the great suggestions. It's great to have a source like this when life baffles you! :biggrin:
I'm sure I will have more questions in the future.
 
Anytime that you cut conventional, it will leave the part fuzzy whether it be steel, aluminum, or plastic. You can take a bigger bite conventional cutting, then take a .005-.010 cleanup cut by climb cutting.
 
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