Precision tools

9 tools for optimal machining of aluminum

Light, stable, and versatile: Aluminum is indispensable in production. However, machining poses special requirements for tools and processes. These are the best solutions for precise and economical machining.

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Aluminum is a versatile material that is used in all sectors of the economy, but machining it poses a number of challenges.
Aluminum is a versatile material that is used in all sectors of the economy, but machining it poses a number of challenges.

Aluminum is one of the most important materials in modern manufacturing. Whether in the automotive industry, mechanical engineering, or aerospace, its combination of low weight, high strength, and good corrosion resistance makes the material almost indispensable. However, machining aluminum poses special requirements for tools and processes. Choosing the wrong solution here risks not only quality issues but also unnecessary costs due to increased wear and longer processing times.

The challenge lies in the material properties: aluminum is relatively soft but tends to form built-up edges. This can impair surface quality and significantly reduce the tool's lifespan. Additionally, heat dissipation during machining plays a central role, especially at high cutting speeds, as is common in mass production.

Therefore, tools are needed that are not only sharp and precise but also have special geometries and coatings to minimize these effects. In our gallery, we present some of these special precision tools:

The solid carbide roughing end mills OptiMill-Alu-Wave for aluminum materials fully utilize the capabilities of the fastest machines available on the market, achieving a material removal rate of up to 21 liters per minute. It is available in diameter ranges from 12 to 25 millimeters with short, medium, and long overhang lengths. Additional variants are configurable, supporting contour-close roughing.
The Ramping Cutter M2331 from Walter is designed for roughing and finishing operations and enables efficient and process-secure machining thanks to positive cutting edge geometry, stable 90-degree shoulders, and high runout accuracy. It is particularly suitable for combined milling strategies such as ramping, face milling, and pocket milling.
The high-performance thread tap Garant Master Tap Alu was specially developed for aluminum alloys and non-ferrous metals. The combination of powder metallurgical cutting material, latest generation DLC coating, and exclusive geometry makes it a good choice in aluminum machining.
Crucial for efficient aluminum machining is that the tool matches the alloy. Hypereutectic alloys (> 17 percent silicon content) require extremely robust coatings, while alloys with low silicon content often cause problems with long chips that can lead to chip jams. Müller Precision Tools has therefore developed specific tool configurations for each application, precisely tailored to the aluminum alloy to be machined.
Thanks to a 3D printing process, Iscar's Heli3Mill-JHP corner mill features flow-optimized coolant channels with coolant outlet directly to the side of the chip chamber. This improves chip control and tool life through significantly improved heat dissipation during aluminum machining.
With its globally unique innovation, the laser-based processing of diamond coatings, the Iguana Laser Series from Zecha aims to set new standards in machining technology and redefine the lifespan of milling tools and drills. The Iguana technology is specially developed for non-ferrous metals, copper, colored or precious metals, as well as highly abrasive plastics or non-ferrous alloys - and thus also suitable for aluminum.
Horn offers a wide portfolio of optimized tools for the economical machining of light metals. The standard program of the DM 20 to DM 90 series stands for process-secure machining of aluminum, non-ferrous metals, and technical plastics in its diversity.
The geometry of the AluLine roughing cutter from Ceratizit is designed for maximum stability and highest material removal rates without compromising process security. The upGRADE carbide substrate CT-GS20Y used in the manufacture of the cutter, with a verifiable Product Carbon Footprint (PCF), consists of 99% recycled carbide and offers an exceptional combination of toughness and wear resistance.
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