Aluminum cutter
With years of experience and expertise, we are a leading manufacturer of aluminum milling cutters, specializing in producing high quality and precise milling tools that meet the most demanding requirements of our customers in various industries.
At Lehmann Präzisionswerkzeuge GmbH, you will find a wide range of aluminum milling cutters with long tool life, great toughness and polish-ground cutting edges. Here we have the right solid carbide end mill for every alloy.
At Lehmann Präzisionswerkzeuge GmbH, you will find a wide range of aluminum milling cutters with long tool life, great toughness and polish-ground cutting edges. Here we have the right solid carbide end mill for every alloy.
- many years of experience in the field of aluminum machining
- long-term partnership
- tools that are tailored to your needs
Experience
since 1991
Employees
more than 110
Made in Germany
100%
Certification
according to DIN EN ISO 9001
Advantages of our aluminum cutters
- high toughness, edge strength and temperature resistance thanks to hard metal
- cutting edges and chip spaces polish-ground -> surfaces particularly smooth
- burr-free machining
- optimum surface finish
- no finishing necessary
- maximum cutting values
- special sizes available at short notice
We are here for you
If you have any questions about these or other topics, our friendly staff will be happy to help you at any time.
Benefit from the many advantages offered by Lehmann Präzisionswerkzeuge GmbH.
Benefit from the many advantages offered by Lehmann Präzisionswerkzeuge GmbH.
The right aluminum cutter for cutting aluminum
When cutting aluminum, the most important thing is stability. Here, the shorter and thicker the aluminum cutter, the more stable it is. And the more stable it is, the less it vibrates and the better the surfaces will be. In addition, there are other points to consider when choosing aluminum milling cutters. We have summarized the most important of them for you here.
The number of cutting edges
Today, aluminum milling cutters can be found in many designs. An important difference is the number of cutting edges.
Here there are single-edged versions, but also those with 2, 3 or 4.
Which of these is the right one for the respective application depends on the hardness of the material.
Here there are single-edged versions, but also those with 2, 3 or 4.
Which of these is the right one for the respective application depends on the hardness of the material.
The advantages of multi-flute aluminum cutters :
The advantages of few cutting edges:
Which variant is most suitable depends primarily on the hardness of the material. In general, aluminum cutters with one or a few cutting edges are more suitable for softer materials. This is because erosion is not such a big problem here, and cooling is more important. For harder materials such as aluminum, it is more common to use a two-flute cutter, since wear plays a more important role due to the greater hardness. Variants with three cutting edges are only used for very hard non-ferrous metals such as certain aluminum alloys, brass and some ferrous materials.
- The cutting edge is a wear part. The more cutting edges share the work, the lower the wear on each of them - the tool life is increased.
- A larger number of cutting edges means greater stability. This is due to the fact that there are fewer empty spaces and the tool rests on the workpiece with a larger surface area.
- The larger cross-section with more cutting edges increases heat dissipation towards the collet - better cooling than with single cutters.
- The more cutting edges there are, the smaller the chips and the smoother the surface.
The advantages of few cutting edges:
- The fewer cutting edges there are, the larger the free surface of the flute - The risk of clogging is lower. The chips can be better removed to the outside.
- The cutter dips into the material more easily.
Which variant is most suitable depends primarily on the hardness of the material. In general, aluminum cutters with one or a few cutting edges are more suitable for softer materials. This is because erosion is not such a big problem here, and cooling is more important. For harder materials such as aluminum, it is more common to use a two-flute cutter, since wear plays a more important role due to the greater hardness. Variants with three cutting edges are only used for very hard non-ferrous metals such as certain aluminum alloys, brass and some ferrous materials.
The cutting edge shape of the aluminum cutters
The cutting edge is available in two different versions, with a stocky blunt and with a pointed shape.
Strangled cutting edge:
In most cases, stocky cutting edges are manufactured with a face grinding. Here, the face runs flat and level. This shape has a decisive advantage. The stability is particularly high. However, plunging is not quite as easy as with pointed cutting edges. Also, the cutting result is not as good with materials of lower strength.
Pointed cutting edge:
The pointed cutting edges are usually designed with a fishtail grinding. With its v-shaped steep course, it penetrates the workpiece particularly well. A disadvantage of this shape, however, is the shorter tool life. Moreover, the ground often has a poorer surface.
For aluminum, it is best to use a pointed cutting edge with a sharp bevel. The flutes should be positioned as large as possible so that the chips can be easily removed.
- solid cutting edge
- rather blunt
- less fine grinding
- chips accumulate faster
- suitable for solid materials
In most cases, stocky cutting edges are manufactured with a face grinding. Here, the face runs flat and level. This shape has a decisive advantage. The stability is particularly high. However, plunging is not quite as easy as with pointed cutting edges. Also, the cutting result is not as good with materials of lower strength.
Pointed cutting edge:
- thin cutting edge body
- sharp shape
- larger clearance - chips can be more easily directed to the outside later on
- suitable for materials with lower density
The pointed cutting edges are usually designed with a fishtail grinding. With its v-shaped steep course, it penetrates the workpiece particularly well. A disadvantage of this shape, however, is the shorter tool life. Moreover, the ground often has a poorer surface.
For aluminum, it is best to use a pointed cutting edge with a sharp bevel. The flutes should be positioned as large as possible so that the chips can be easily removed.
The twist
Another aspect that must be considered is the twist. The direction here determines where the chips wind out of the workpiece, on the top or the bottom of the workpiece. This is relevant because cleanliness is poorer at the corresponding milling edges. In the case of right-hand helical milling cutters, this happens at the top. However, there is the advantage here that the chips are conveyed out immediately during grooving. With left-hand helical aluminum cutters, the edge remains clean. However, the chips are pressed into the groove. The right-hand helix variant is also referred to as "upcut". The left-hand helical spindles, on the other hand, are referred to as "downcut".
Other aspects that must be considered in the selection process
In addition, other factors play a role in the selection of aluminum cutters. The following aspects should be mentioned here in particular:
- Toothing
- Coating
- Cutting edge length
- Clearance
- Diameter
- Cutter substrate
- Shank shape
Practical tips for working with the aluminum cutter
The choice of the right tool:
The right operating parameters:
Cooling and lubrication:
- The milling cutter should always be chosen depending on the material.
- Opt for the shortest possible milling cutter and clamp it as far as possible.
The right operating parameters:
- Follow the recommended values when machining aluminum or aluminum alloys. During the milling process, you can adjust the parameters to optimize the operation.
- For aluminum, you should set the speed of the aluminum cutter slightly lower and the feed rate quietly slightly higher.
- The higher the feed rate during roughing and the lower the speed at the milling motor, the less heat is generated by friction.
- When finishing, the speed can be set a little higher and the feed a little lower, as less heat is generated here.
- You should not mill deeper than 2 - 3 cutting diameters. Deeper grooves should be milled in several passes with a smaller depth. This increases the stock removal rate and thus the economic efficiency.
- Internal contours are best milled clockwise and external contours counterclockwise.
Cooling and lubrication:
- It is important that the aluminum cutter is cooled at all times, either by lubricating emulsion or compressed air.
- A lubricating solution will improve surface quality and tool life.
- If cooling is not possible, the speeds should be selected according to the recommended specifications.
The most important information about aluminum milling
Challenges in aluminum milling
Thanks to its mechanical properties, aluminum is ideally suited for the production of precise components with polished surfaces. An accuracy of one thousandth of a millimeter is no problem here.
To ensure that this accuracy is achieved, however, a few things must be taken into account when milling with aluminum cutters. First of all, there is the heat generated. Unlike wood and steel, aluminum can become soft and the cutting edge can stick together due to the strong heat generated during milling. The chips are then no longer removed, the chip space becomes clogged and the milling process stops. In the worst case, the milling tool breaks.
Reliable cooling is therefore indispensable when milling aluminum. Here you can choose between minimum quantity lubrication or compressed air. The second variant offers the advantage that it also blows through the chip space at the same time, which prevents clogging.
To ensure that this accuracy is achieved, however, a few things must be taken into account when milling with aluminum cutters. First of all, there is the heat generated. Unlike wood and steel, aluminum can become soft and the cutting edge can stick together due to the strong heat generated during milling. The chips are then no longer removed, the chip space becomes clogged and the milling process stops. In the worst case, the milling tool breaks.
Reliable cooling is therefore indispensable when milling aluminum. Here you can choose between minimum quantity lubrication or compressed air. The second variant offers the advantage that it also blows through the chip space at the same time, which prevents clogging.
Determine the speed and the feed rate
When milling, the following principle applies: the higher the cutting speed, the smoother the surface. However, the cutter wear of the aluminum cutter also increases with the cutting speed. Therefore, the optimum balance between performance and wear must be found. Let's take hard aluminum as an example. Here, a cutting speed VC of 100 - 200 m/min is selected. How high the specific feed fZ is depends on the diameter of the cutting edge. Here you keep to the following guide values:
To determine the speed n, use the following formula:
n [rpm] = (Vc [m/min] * 1,000 / (3.14 * Ø d1 [mm]).
Once you have the value for the speed, you can then calculate the ideal feed per tooth (cutting edge) fZ and revolution:
f [mm/min] = n * fz * z
- Cutting edge diameter Ø d1 (in mm)
- Specific feed (mm / revolution and cutting edge)
To determine the speed n, use the following formula:
n [rpm] = (Vc [m/min] * 1,000 / (3.14 * Ø d1 [mm]).
Once you have the value for the speed, you can then calculate the ideal feed per tooth (cutting edge) fZ and revolution:
f [mm/min] = n * fz * z
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Aluminum cutter
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