Computer numerical control (CNC) machining accounts for a larger portion of the total energy drawn from the grid by the manufacturing sector. I have used kerosene as lube/coolant when trying to cut or thread the stuff.Due to the rising concerns related to the depletion of fossil fuel sources, and the climate change associated to the usage of such sources for electricity generation, there is a high pressure for diminishing the energy consumption of all the industrial sectors in order to mitigate the negative impacts associated to the energy required to manufacture a product. Have heard of people making pistons and things like that so real high strength stuff.Īvoid 1000 or 3000 series, real soft stuff for forming and utensils. Somewhat harder to get is 7058, mainly aircraft use, but is heat treatable. I've had reasonable results with 5083 (I think!) which is a marine grade but otherwise similar to 6063. Its quite hard and machines really nicely and is so much more forgiving than 6000 series which is soft enough to 'smear' and load Workhardened to T6 and heat treated to H4. The good thing about the 2000 series (copper additives) is that the material can be heat treated in addition to ordinary workhardening.
Quantities from an aircraft manufacturer and its worth a bloody fortune. The current material is 2024 and I use it for model aircraft undercarts and the likes. If your machine can't go that fast, and you mentioned 8,000 rpm, then the feed rate for roughing should be about 460mm/min and for finishing 265mm/min at 8,000 rpm.ĭural I think is 2014 or maybe 2017 any not much in use anymore. With a 4 flute cutter they will always get stuck because they get trapped in the flute even if you've got good coolant. I generally use a single flute cutter with all aluminium alloys and can still have chip clearance issues if my misters are not getting the chips away.
You have to be completely paranoid about re-cutting chips, so you need good coolant flood or high pressure mist to blow the chips away otherwise they get stuck to the cutter and it'll break. The most important thing I've found is chip clearance. The one I use suggests for a 3mm dia 2 flute cutter with a cut depth of 1.5mm the spindle speed should be 16,000 rpm and feed rate 950mm/min for roughing (notice I'm European and don't use inches) and 14,600 rpm and 485mm/min for finishing. There are software tools to help with feeds and speeds. In alloy you want either a single flute or 2 flute cutter.
I would suggest that your using the wrong cutter.
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