Aluminium can be an easy to machine material because it is much softer than the likes of hardened steel and tough super alloys like inconel. To make life easier and maximise your machining capabilities, you will need to use the correct geometry tooling, high precision collets and suitable tool holders.

Its composition means aluminium is a soft and sticky material with a low melting point. What this means is that, when machining, there is often a build up of swarf as the material ‘gums up’ the tool on its cutting edge. This is commonly called a built-up edge and in turn, this can severely limit the effectiveness of the tool with potentially a poorer surface finish and a reduction in speeds and feeds.

Modern milling cutters (HSS, Powder Metal or Carbide) for ferrous metals usually feature some type of coating, like TiN or TiAlN, to improve tool life or increase its performance. However, on aluminium (which is non-ferrous) and other soft materials like copper and plastics, a coating will elevate the risk because the material will stick to this coating. Therefore, we would recommend that when machining aluminium an uncoated milling cutter should be used, unless the coating is specifically designed for non-ferrous materials, like a DLC (diamond-like carbon) coating.

There are some other features typical of aluminium milling cutters which help to avoid the problem of material build-up including:

• Deeper flute pockets.
• Lapped & polished flutes.
• Sharp cutting edge.

Deep flute pockets mean that the cutter doesn’t clog as quickly, so the tool can be run for longer and at higher cutting data. Lapped and polished flutes enable excellent chip flow when machining soft materials, whilst a sharp cutting edge gives quicker metal removal rates.

Most aluminium milling cutters will feature the above attributes. However, which range you choose will depend on various factors like:

• Cost.
• Machining setup.
• Application type.

Cutwel supply a range of aluminium milling cutters to suit all budgets and applications. Below is a summary of each range and what situations each cutter is best suited for.

Starting with our lowest cost option, the Alu-Cut range from YG-1 are made from a tough HSS substrate, and it best suited for use on manual machines or where machining set-ups are unstable. This is because HSS is more forgiving over a carbide substrate and is less likely to chip should there be any vibrations present in the machining process, or if the component isn’t held rigidly.

Our range of Alu-Cut HSS milling cutters include 2 or 3 flute variants in either a standard or rougher profile. It features deep flute pockets for improved performance in soft material machining. Rippers also have a chamfer preparation on the tool edge to protect the tool on first contact, hence improving the tool life.

Our most popular range, YG-1’s Alu Power is the perfect all-round carbide milling cutter designed specifically for non-ferrous materials like aluminium. Its micrograin carbide substrate ensures increased performance, tool life and wear resistance over the HSS range in stable machining conditions. Meanwhile, the special geometry for aluminium ensures the best chip control and surface finish.

In terms of variation, Alu Power is the most comprehensive range we supply. It encompasses a huge range of lengths, styles and geometry types. Both slot drills and end mills are available, with long length variants give superior chip evacuation in deeper applications. Ripper style cutters enable faster and more extreme metal removal rates.

The Alu Power range is not just designed for aluminium (as the name may suggest), but also encompasses copper, brass and plastic. YG-1 have also created a range of cutters specifically for machining plastics called Plastic-Cut.

To complement our Alu Power range, Korloy’s A+ End Mills are our first choice high performance cutter for aluminium finishing applications. These 2 or 3 flute cutters feature a 50° helix angle and u-shaped flutes to provide an extreme quality surface finish. Its cutting edge features high rigidity to ensure high productivity. A+ End Mills are the best way to get a mirror surface finish using a standard carbide aluminium milling cutter.

Alu Power HPC is the ultimate milling cutter for aluminium metal removal. YG-1’s flagship non-ferrous range offers speed, strength and sharpness, with effective chip evacuation at high feed rates with lower cutting forces. From side cuts to rough cuts to aggressive ramping, no cutter withstands extreme radial forces better – or longer. Its 37° helix design can operate at lower speeds with higher efficiency.

Although previously it was stated that aluminium milling cutters should be uncoated, the HPC range bucks this trend by featuring an optional DLC (diamond like carbon) coating. This coating is designed for hard or abrasive aluminium substrates such as aluminium used in aerospace and high silicone aluminium alloys.

For non-hard aluminium we would recommend the uncoated HPC range, which includes a range of 3 flute slot drills, with features like an extended neck and corner radius increasing the application range and tool life. Furthermore, these cutters are highly effective in vertical ramping up to 20° and step-over plunging applications.

For any advice or more information on our range of aluminium milling cutters please get in touch today by calling 01924 869610, email sales@cutwel.net or view our full range online at www.cutwel.co.uk.