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 dem come and spoil tools and finish. You go learn settings, shape, and coolant changes dat limit BUE, rubbing, and early edge break.
How workhardening happen in 6061How BUE start on cutting edgesEffects on tool wear and chippingSurface finish and size errorsSettings changes to cut BUETool and coolant picks to limit BUELesson 2Selecting tool materials and coatings for aluminum (carbide, uncoated vs DLC/AlTiN)Here you go compare carbide types and coating choices for aluminum 6061. The part explains when to use uncoated, DLC, or AlTiN tools, thinking about sticking, heat, built-up edge, and cost in dry and coolant help milling.
Small grain carbide types for aluminumUncoated tools and sticking behaviorDLC coatings for rough or dry cuttingWhen AlTiN good for aluminumCoating effect on heat and chip flowCost against performance choicesLesson 3Coolant and lubrication strategies for aluminum (flood coolant, mist, or dry with lubricant)Here you go compare coolant and lubrication ways for 6061, including flood, mist, MQL, and near-dry cutting. The part covers heat take away, chip flush, safety, and how lubrication cut built-up edge and better surface finish.
Flood coolant flow and nozzle pointMist and MQL setup thinksDry cutting with outside lubricantCoolant mix for aluminum mixesHandling foam and rust riskCoolant keep up and filterLesson 4Choosing number of flutes and tool diameters trade-offs for chip evacuation and spindle powerHere you go learn how flute number and tool size affect chip take out, spindle load, and steady in 6061. The part guide pick of 2, 3, or 4 flutes and size for slotting, roughing, and finishing work.
Two-flute tools for chip take outThree-flute cutters for roughing 6061Four-flute tools for finishing passesSize choice against spindle powerChip pack and slotting behaviorBalance steady and reach needsLesson 5Metallurgical properties of aluminum 6061 relevant to milling (strength, thermal conductivity, chip formation)You go study the metal traits of 6061 dat affect milling, including strength, hardness, heat carry, and chip make. The part link temper, heat make, and chip shape to tool wear, chatter, and surface finish.
6061 mix and common tempersYield strength and machinability linksHeat carry and heat flowChip make and chip thicknessTemper effect on burrs and finishLeft stresses and part bendLesson 6Tool life estimation and monitoring methods for batch productionThis part show ways to guess and watch tool life in batch work. You go use wear rules, Taylor equations, counters, and in-work signals to plan tool changes and avoid waste or big breaks.
Tool wear kinds and break modesSetting end-of-life wear rulesBasic Taylor tool life equation useUsing part and time based countersSpindle load and shake watchTool life track 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 part detail tool types and sizes for pocketing and holemaking in 6061. You go compare face mills, end mills, slotters, drills, annular cutters, and helical interpolation, focus on steady, chip take out, and cycle time.
Face mill size for surfacing 6061Flat end mills for pockets and slotsHigh-feed and slotting waysTwist drills against annular cuttersHelical interpolation for exact boresTool length and steady pickLesson 8Tool geometry for aluminum: helix angle, rake, margin, polished flutes to prevent BUEThis part explains cutter shape features dat better aluminum work. You go learn how helix angle, rake, margin width, and polished flutes affect cutting force, chip take out, and fight to built-up edge in 6061.
High rake angle for free cuttingHelix angle picks for 6061Margin width and tool guidePolished flutes and chip take outCorner prep and edge hone sizeShape to cut built-up edgeLesson 9Climb vs conventional milling in aluminum: advantages, when to use eachYou go compare climb and conventional milling ways in aluminum 6061. The part explains chip thickness shapes, tool bend, backlash worries, and when each way good for roughing, finishing, and thin-wall parts.
Chip thickness in climb vs conventionalBacklash and machine state limitsRoughing way pick in 6061Finishing passes and wall steadyTool bend and size errorEntry, exit, and hold effectsLesson 10Typical feed, speed, and depth-of-cut ranges for roughing and finishing aluminum 6061 (tabulated for common tool diameters)This part set practical start feeds, speeds, and cut depths for roughing and finishing 6061. You go compare ranges by tool size, work type, and machine steady, then learn how to change safe from table values.
Roughing vs finishing setting goalsTable ranges by tool sizeChange for spindle power and steadyEffect of side vs deep engagementChip load per tooth and feed mathScale values for small and big tools
