Aluminum Feeds & Speeds Calculator 2026
Calculate optimal cutting parameters for all aluminum alloys. Get recommended speeds, feeds, and avoid built-up edge with proper tooling selection.
Calculate Aluminum Parameters
Aluminum Machining: Complete Guide 2026
Aluminum is one of the most widely machined materials due to its excellent machinability, light weight, and good strength-to-weight ratio. However, achieving optimal results requires understanding alloy-specific characteristics and proper tooling selection.
Understanding Aluminum Series
| Series | Alloy Element | Machinability | Applications |
|---|---|---|---|
| 1xxx | Pure Al (>99%) | Poor - gummy | Electrical, chemical |
| 2xxx | Copper | Good - 2011 excellent | Aircraft, fasteners |
| 5xxx | Magnesium | Moderate - stringy chips | Marine, fuel tanks |
| 6xxx | Mg + Si | Excellent | General purpose, 6061 |
| 7xxx | Zinc | Good | Aerospace, high strength |
| Cast | Silicon (7-12%) | Abrasive - use PCD | Automotive, housings |
Built-up Edge (BUE) Prevention
Built-up edge is the #1 challenge in aluminum machining. Soft aluminum welds to the cutting edge, degrading surface finish and dimensional accuracy.
❌ Causes of BUE
- • Low cutting speeds
- • Wrong tool coating (TiAlN, AlTiN)
- • Dry machining soft alloys
- • Dull or rough cutting edges
- • Insufficient chip evacuation
✓ BUE Prevention
- • Increase cutting speed
- • Use ZrN or DLC coatings
- • Apply MQL or flood coolant
- • Use polished flute tools
- • Use 2-3 flute end mills
Tool Selection for Aluminum
Coatings
Best: ZrN (gold), DLC (black), Uncoated polished
Avoid: TiAlN, AlTiN (contain aluminum, causes adhesion)
Flute Count
Recommended: 2-3 flutes for chip evacuation
Avoid: 4+ flutes cause chip packing
For Cast Aluminum (High Si)
Best: PCD (Polycrystalline Diamond) for production
Alternative: Uncoated carbide with frequent replacement
Frequently Asked Questions
Aluminum cutting speeds are much higher than steel. For 6061-T6 with carbide tooling: milling 250-600 m/min (800-2000 SFM), turning 300-900 m/min (1000-3000 SFM). Softer alloys like 1100 can go even faster. With PCD tooling, speeds can exceed 1000 m/min.