rpm and feed rate for aluminum

1. Years ago, I learned RPM=CS*4/D. This you can do in your head and it's close enough for most work. CS for 6061 aluminum should be around 250 FPM with a HSS cutter. So, RPM=250-4/.5 or 2000.

2. Feed rate is something that you can look at any book, but it won't tell you enough. If you're using a HSS end mill, do you have regular or high helix? If you have a regular helix end mill, you can usually get .001" per tooth with aluminum (maybe more, that's conservative). So, .001*4*2000=8 in/min. This is a starting place.

3. TIN, ALN, and other coatings are put on cutters to make the edges last longer. There are 2 ways of looking at this, run same speeds and feeds as uncoated and get 10% longer life on the tool or run 10% faster and get same tool life. For most home shop use, I don't think that coatings are worth the extra money.
JR

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Thanks roninB4 for quite some insight!

So I should not worry so much about feed and spindle speed then, but rather keeping chips away. This is somewhat a problem atm as I dont have compressed air (another thing that I need cash for...). Now I just spray chips away with my coolant.

Is there a downside of having too little feed (or too fast spindle) other than the longer milling time? I believe I've read somewhere that if the feed is too slow, the tool will gnaw on the stock instead of actually cutting. Is this correct?

So if I understand correctly; the packing of flutes can come of two factors: 1: too much chips not being properly evacuated; and/or: 2: too hot, which melts the aluminium to the cutter.


Thanks again for very insightful answers It's much appreciated!!
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Thanks for the link mcphil - I've signed up for a trial.Thanks roninB4 for quite some insight!So I should not worry so much about feed and spindle speed then, but rather keeping chips away. This is somewhat a problem atm as I dont have compressed air (another thing that I need cash for...). Now I just spray chips away with my coolant.Is there a downside of having too little feed (or too fast spindle) other than the longer milling time? I believe I've read somewhere that if the feed is too slow, the tool will gnaw on the stock instead of actually cutting. Is this correct?So if I understand correctly; the packing of flutes can come of two factors: 1: too much chips not being properly evacuated; and/or: 2: too hot, which melts the aluminium to the cutter.Thanks again for very insightful answersIt's much appreciated!!

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