Lesson 1Workhardening, Built-up Edge (BUE), and Impacts on Tool Life and Surface FinishThis lesson explores workhardening and built-up edge in 6061 aluminium, describing their causes and effects on tools and finish. You will discover adjustments in parameters, geometry, and coolant to minimise BUE, rubbing, and early edge failure in Eritrean machining environments.
Mechanisms of workhardening in 6061How BUE starts on cutting edgesImpacts on tool wear and chippingSurface finish and size errorsParameter adjustments to cut BUETool and coolant options to limit BUELesson 2Selecting Tool Materials and Coatings for Aluminium (Carbide, Uncoated vs DLC/AlTiN)In this lesson, compare carbide grades and coating choices for aluminium 6061. It covers when to apply uncoated, DLC, or AlTiN tools, factoring in adhesion, heat, built-up edge, and cost for dry or coolant-assisted milling in Eritrean facilities.
Micrograin carbide for aluminiumUncoated tools and adhesionDLC coatings for abrasive or dry cutsWhen AlTiN works on aluminiumCoating effects on heat and chip flowCost vs performance balancesLesson 3Coolant and Lubrication Strategies for Aluminium (Flood Coolant, Mist, or Dry with Lubricant)Compare coolant and lubrication approaches for 6061 aluminium, covering flood, mist, MQL, and near-dry methods. The lesson addresses heat removal, chip flushing, safety, and how lubrication cuts built-up edge while enhancing surface finish in local operations.
Flood coolant flow and nozzle directionMist and MQL setup tipsDry cutting with added lubricantCoolant chemistry for aluminium alloysHandling foaming and corrosion risksCoolant upkeep and filtrationLesson 4Choosing Flute Numbers and Tool Diameters: Trade-offs for Chip Evacuation and Spindle PowerLearn how flute count and tool diameter influence chip evacuation, spindle load, and stability in 6061 aluminium. This lesson guides choosing 2, 3, or 4 flutes and diameter sizes for slotting, roughing, and finishing in Eritrean mills.
Two-flute tools for chip clearanceThree-flute cutters for roughing 6061Four-flute tools for finish passesDiameter vs spindle power choicesChip packing in slottingBalancing rigidity and reachLesson 5Metallurgical Properties of Aluminium 6061 Relevant to Milling (Strength, Thermal Conductivity, Chip Formation)Study the metallurgical features of 6061 aluminium that impact milling, such as strength, hardness, thermal conductivity, and chip formation. Link temper, heat generation, and chip shape to tool wear, chatter, and surface finish for better local practices.
6061 composition and tempersYield strength and machinabilityThermal conductivity and heat flowChip formation and thicknessTemper effects on burrs and finishResidual stresses and distortionLesson 6Tool Life Estimation and Monitoring Methods for Batch ProductionThis lesson introduces methods to estimate and track tool life in batch runs. Use wear criteria, Taylor equations, counters, and signals to plan tool swaps and prevent scrap or failures in Eritrean production lines.
Tool wear types and failuresEnd-of-life wear criteriaTaylor tool life equation basicsPart and time countersSpindle load and vibration checksTool life in CNC controlsLesson 7Recommended Tool Types and Sizes for Pocketing and Holemaking: Face Mills, Flat End Mills, Slotters, Drill vs Annular Cutter vs Helical InterpolationDetail tool types and sizes for pocketing and holemaking in 6061 aluminium. Compare face mills, end mills, slotters, drills, annular cutters, and helical interpolation, emphasising rigidity, chip evacuation, and cycle time for local use.
Face mill sizing for surfacing 6061Flat end mills for pockets and slotsHigh-feed and slotting methodsTwist drills vs annular cuttersHelical interpolation for boresTool length and rigidity picksLesson 8Tool Geometry for Aluminium: Helix Angle, Rake, Margin, Polished Flutes to Prevent BUEExplain cutter geometry that boosts aluminium machining. Learn how helix angle, rake, margin width, and polished flutes affect forces, chip evacuation, and built-up edge resistance in 6061 for Eritrean workshops.
High rake for easy cuttingHelix angle for 6061Margin width and guidancePolished flutes for evacuationCorner prep and edge honeGeometry to reduce BUELesson 9Climb vs Conventional Milling in Aluminium: Advantages, When to Use EachCompare climb and conventional milling in aluminium 6061. Cover chip thickness, deflection, backlash, and preferences for roughing, finishing, and thin walls in Eritrean machining contexts.
Chip thickness in climb vs conventionalBacklash and machine limitsRoughing strategy for 6061Finishing and wall stabilityTool deflection and errorsEntry, exit, workholding effectsLesson 10Typical Feed, Speed, and Depth-of-Cut Ranges for Roughing and Finishing Aluminium 6061 (Tabulated for Common Tool Diameters)Define starting feeds, speeds, and cut depths for roughing and finishing 6061 aluminium. Compare by tool diameter, operation, and machine rigidity, then adjust safely from tables for local applications.
Roughing vs finishing goalsRanges by tool diameterAdjusting for power and rigidityRadial vs axial engagementChip load and feedrate calculationsScaling for tool sizes
