Need help with finish on Al 6061 T6

[mike561h]

Hi friends.

 

Got the dimensions all goo but the finish sucks. Using carbide 2 flute 2 inch LOC.

Was running at 2300 and 15 IPM. I am sure someone here can help me get a nice finish.

I was stepping doebn .250 and doiong the finish pass after each roufh cut. Only removing about .070

[Chris Rizzo]

Get a 3 flute endmill. Finish only at final depth, taking .005-.010 off.

[Oscar R.]

Also, if your using uncoated carbide, Aluminum tends to bond to it leaving behind a crappy looking finish.

Try using a coated or even plain HSS cutter, 3 or 4 flute, .01 finish pass at or as close to final finish depth as you can get.

[huskermcdoogle]

+1 for three flute. What diameter?

[overthecrossbar]

3flute neck relieved Hanita Alusurf .01" finish at all depths, speed and feed depends on wall thickness.

[K2csq7]

If you don't have the best coolant, try spraying the surface with white lithium grease then cut it (with your coolant still on).

Can you describe the "bad finish" is it chatter? vibration? material welding itself to the finish?

.07 is a huge finish pass. +1 to chris .005/.010 max. And only one pass at final depth...

[90rsgnuguy42]

I've also had good luck with SkiCarb end mills for long length small diameter finishing tools in aluminum. Especially if you're looking for chatter free inside corners.

[jeff]

Also, if your using uncoated carbide, Aluminum tends to bond to it leaving behind a crappy looking finish.

Try using a coated or even plain HSS cutter, 3 or 4 flute, .01 finish pass at or as close to final finish depth as you can get.

 

Not entirely true.

You WANT an uncoated bright finish carbide endmill, if you absolutely need a coating, only get a coating that is made for aluminum.. TialN is not good.. ZrN is good.

I use OSG Blizzards exclusively in Aluminum, and they have no coating, with a bright finish, I get an excellent finish.

1/2" dia 3 flute

12k rpm

220IPM roughing feedrate.