Lesson 1Workhardening, built-up edge (BUE), and effects on tool life and surface finishThis part looks at workhardening and built-up edge in 6061, showing how they happen and harm tools and finish. You'll learn settings, tool shapes, and coolant tweaks to cut down BUE, rubbing, and early edge wear.
Mechanisms of workhardening in 6061How BUE initiates on cutting edgesEffects on tool wear and chippingSurface finish and dimensional errorsParameter changes to reduce BUETool and coolant choices to limit BUELesson 2Selecting tool materials and coatings for aluminium (carbide, uncoated vs DLC/AlTiN)Here you'll compare carbide types and coatings for aluminium 6061. It explains when to go for uncoated, DLC, or AlTiN tools, looking at sticking, heat, built-up edge, and cost in dry or coolant milling.
Micrograin carbide grades for aluminumUncoated tools and adhesion behaviorDLC coatings for abrasive or dry cuttingWhen AlTiN is acceptable on aluminumCoating impact on heat and chip flowCost versus performance trade-offsLesson 3Coolant and lubrication strategies for aluminium (flood coolant, mist, or dry with lubricant)Here you'll compare coolant and lube options for 6061, like flood, mist, MQL, and near-dry. It covers heat removal, chip clearing, safety, and how lube cuts built-up edge and boosts surface finish.
Flood coolant flow and nozzle aimingMist and MQL setup considerationsDry cutting with external lubricantCoolant chemistry for aluminum alloysManaging foaming and corrosion riskCoolant maintenance and filtrationLesson 4Choosing number of flutes and tool diameters trade-offs for chip evacuation and spindle powerHere you'll see how flute count and tool size impact chip clearing, spindle load, and stability in 6061. It guides picking 2, 3, or 4 flutes and sizes for slotting, roughing, and finishing.
Two-flute tools for chip evacuationThree-flute cutters for roughing 6061Four-flute tools for finishing passesDiameter choice versus spindle powerChip packing and slotting behaviorBalancing rigidity and reach needsLesson 5Metallurgical properties of aluminium 6061 relevant to milling (strength, thermal conductivity, chip formation)You'll study 6061's metal properties affecting milling, like strength, hardness, heat conduction, and chip shape. It links temper, heat buildup, and chip form to tool wear, vibration, and finish.
6061 composition and common tempersYield strength and machinability linksThermal conductivity and heat flowChip formation and chip thicknessEffect of temper on burrs and finishResidual stresses and part distortionLesson 6Tool life estimation and monitoring methods for batch productionThis part covers ways to estimate and track tool life in batches. You'll use wear standards, Taylor formulas, counters, and live signals to time tool swaps and dodge scrap or big breakdowns.
Tool wear types and failure modesDefining end-of-life wear criteriaBasic Taylor tool life equation useUsing part and time based countersSpindle load and vibration monitoringTool life tracking in CNC controlsLesson 7Recommended tool types and sizes for pocketing and holemaking: face mills, flat end mills, slotters, drill vs annular cutter vs helical interpolationThis details tools and sizes for pocketing and holes in 6061. You'll compare face mills, end mills, slotters, drills, ring cutters, and helical boring, eyeing stiffness, chip flow, and time.
Face mill sizing for surfacing 6061Flat end mills for pockets and slotsHigh-feed and slotting strategiesTwist drills versus annular cuttersHelical interpolation for precise boresTool length and rigidity selectionLesson 8Tool geometry for aluminium: helix angle, rake, margin, polished flutes to prevent BUEThis explains cutter shapes that help aluminium work. You'll learn how helix, rake, margin, and shiny flutes affect forces, chip flow, and fighting built-up edge in 6061.
High rake angle for free cuttingHelix angle choices for 6061Margin width and tool guidancePolished flutes and chip evacuationCorner prep and edge hone sizeGeometry to reduce built-up edgeLesson 9Climb vs conventional milling in aluminium: advantages, when to use eachYou'll compare climb and standard milling in aluminium 6061. It covers chip thickness, tool bend, backlash, and when each suits roughing, finishing, or thin parts.
Chip thickness in climb vs conventionalBacklash and machine condition limitsRoughing strategy selection in 6061Finishing passes and wall stabilityTool deflection and dimensional errorEntry, exit, and workholding effectsLesson 10Typical feed, speed, and depth-of-cut ranges for roughing and finishing aluminium 6061 (tabulated for common tool diameters)This sets practical starting feeds, speeds, and cut depths for roughing and finishing 6061. You'll see ranges by tool size, job type, and machine strength, then tweak safely from tables.
Roughing vs finishing parameter objectivesTabulated ranges by tool diameterAdjusting for spindle power and rigidityEffect of radial vs axial engagementChip load per tooth and feedrate mathScaling values for small and large tools
