Aluminum Feeds & Speeds Chart
Quick-look reference data for 6061, 7075, 2024, Mic-6, and cast aluminum milling. Best used as a shop-floor starting chart before you validate alloy, flute, and chip-evacuation details in the calculator.
Need Exact Aluminum Milling Numbers?
Use this chart for a fast first pass. Then move to the aluminum calculator when flute count, coating, stepover, chip evacuation, or built-up-edge risk need a setup-specific answer.
What This Chart Covers Best
First-pass SFM and chip-load ranges for aluminum milling, slotting, and profiling with end mills. Best when you need a quick alloy comparison on the shop floor.
Where It Needs Backup
Drilling, turning, and tapping need feed-per-rev or thread-pitch logic. Face milling and router jobs still need calculator follow-through when stepover and machine limits are decisive.
Best Next Links
Branch to the aluminum calculator, chip-load calculator, or drilling calculator when the cut gets specific.
6061-T6 (General Purpose)
The most common aluminum alloy. Gummy but machines well. Requires high RPM and sharp tools (ZrN or Uncoated).
| Tool Material | Operation | SFM Range | Chip Load (1/2" End Mill) |
|---|---|---|---|
| Carbide (Uncoated/ZrN) | Roughing | 1200 - 2500+ | 0.004" - 0.008" |
| Carbide (Uncoated/ZrN) | Finishing | 1500 - 3000+ | 0.001" - 0.003" |
| Carbide (Uncoated/ZrN) | Slotting (100% WOC) | 1000 - 1800 | 0.003" - 0.005" |
| HSS (High Speed Steel) | General Milling | 400 - 800 | 0.002" - 0.004" |
7075-T6 (High Strength / Aerospace)
Harder and stronger than 6061. Chips break better (short chips). Can take slightly higher tooth loads but slightly lower speeds.
| Tool Material | Operation | SFM Range | Chip Load (1/2" End Mill) |
|---|---|---|---|
| Carbide (Uncoated/ZrN) | Roughing | 1000 - 2000 | 0.005" - 0.009" |
| Carbide (Uncoated/ZrN) | Finishing | 1200 - 2500 | 0.001" - 0.003" |
| Carbide (Uncoated/ZrN) | Slotting | 800 - 1500 | 0.003" - 0.006" |
2024 & Cast Aluminum (Mic-6)
2024 (Copper Alloy)
Tougher than 6061 and usually more adhesion-prone than 7075. Watch chip evacuation and coolant quality.
| SFM | 800 - 1500 |
| Notes | Use Coolant! |
Cast Al (Mic-6 / A356)
Often cleaner-cutting than soft wrought grades, but high-silicon castings are abrasive and can punish the wrong tool fast.
| SFM | 1500 - 3000 |
| Tooling | Carbide Only |
If The Job Is Drilling, Switch Workflows
This chart page is mainly for aluminum milling reference. Use the table below only as a quick drill-speed sense check, then move to the dedicated drilling calculator for peck depth, hole depth, and feed-per-rev validation.
| Drill Size | HSS RPM (300 SFM) | Carbide RPM (600 SFM) | Feed (IPR) | Peck Cycle |
|---|---|---|---|---|
| 1/8" (0.125) | 9,100 | 18,300 | 0.002 - 0.004 | Required > 3xD |
| 1/4" (0.250) | 4,500 | 9,100 | 0.004 - 0.008 | Required > 3xD |
| 3/8" (0.375) | 3,000 | 6,100 | 0.006 - 0.010 | Recommended |
| 1/2" (0.500) | 2,200 | 4,500 | 0.008 - 0.012 | Standard |
Coating Guide: What Color Should Your End Mill Be?
ZrN (Zirconium Nitride)
Color: Gold / Pale Yellow
Best for Aluminum
Excellent lubricity, prevents built-up edge.
Uncoated (Polished)
Color: Silver / Shiny
Excellent
Sharpest edge possible. Great for finishing plastics & Al.
AlTiN / TiAlN
Color: Dark Grey / Purple
DO NOT USE
Contains Aluminum. Will chemically bond to material (gall).
A Note on Cooling
The real rule is not “always flood coolant.” The real rule is never let chips stay in the cut.Soft wrought grades may need MQL or flood coolant to control built-up edge, while harder alloys can often run well with strong air blast. If chips stop clearing, the flute packs and the tool usually fails before the formula does.
Frequently Asked Questions
What SFM should I use for 6061-T6 aluminum with carbide?
Use this chart as a first-pass range, not a final release number. For 6061-T6 with carbide, a practical milling start point is roughly 800–1,000 SFM for conventional roughing and higher for optimized HEM/HSM paths. After that, confirm flute count, coolant, radial engagement, and chip evacuation in the aluminum calculator.
What is the recommended chip load for milling aluminum?
For a quick chart lookup, typical milling chip loads are about 0.002–0.004 IPT on a 1/4-inch tool and 0.003–0.006 IPT on a 1/2-inch tool. Treat those as reference windows only, because coating, flute count, alloy, and slotting versus side milling will all move the safe answer.
How do speeds differ between 6061 and 7075 aluminum?
7075-T6 is harder (Brinell 150 vs 95), so speeds are 10–20% lower. 7075 roughing: 600–900 SFM vs 6061: 800–1,000. Feed rates are similar; the key difference is surface speed.
Should I use flood coolant or mist for aluminum?
Flood coolant at 6–10% concentration is recommended. It prevents built-up edge (BUE) and aids chip evacuation. Air blast or mist works for finishing with coated tools.
What are the best tool coatings for aluminum?
Uncoated polished carbide or ZrN coating. ZrN resists aluminum adhesion. Avoid TiAlN and AlTiN — the aluminum content causes welding/galling.