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 start and harm tools and finish. You will learn changes in settings, shapes, and coolants that stop BUE, rubbing, and early edge breaking.
Ways workhardening happens in 6061How BUE starts on cutting edgesEffects on tool wear and breakingSurface finish and size mistakesSetting changes to cut BUETool and coolant picks to limit BUELesson 2Selecting tool materials and coatings for aluminium (carbide, uncoated vs DLC/AlTiN)Here you will compare carbide types and coating choices for aluminium 6061. The part shows when to use uncoated, DLC, or AlTiN tools, thinking about sticking, heat, built-up edge, and cost in dry or coolant milling.
Small grain carbide types for aluminiumUncoated tools and sticking waysDLC coatings for rough or dry cuttingWhen AlTiN works on aluminiumCoating effect on heat and chip flowCost against work trade-offsLesson 3Coolant and lubrication strategies for aluminium (flood coolant, mist, or dry with lubricant)Here you will compare coolant and lubrication ways for 6061, like flood, mist, MQL, and almost dry cutting. The part covers heat taking away, chip cleaning, safety, and how lubrication cuts built-up edge and betters surface finish.
Flood coolant flow and nozzle pointingMist and MQL setup thoughtsDry cutting with outside lubricantCoolant mix for aluminium mixesHandling foam and rust dangerCoolant care and cleaningLesson 4Choosing number of flutes and tool diameters trade-offs for chip evacuation and spindle powerHere you will learn how flute number and tool size affect chip taking out, spindle load, and steady work in 6061. The part guides picking 2, 3, or 4 flutes and size for slotting, roughing, and finishing jobs.
Two-flute tools for chip taking outThree-flute cutters for roughing 6061Four-flute tools for finishing runsSize choice against spindle powerChip packing and slotting waysBalancing strongness and reach needsLesson 5Metallurgical properties of aluminium 6061 relevant to milling (strength, thermal conductivity, chip formation)You will study the metal traits of 6061 that affect milling, like strength, hardness, heat passing, and chip making. The part links temper, heat making, and chip shape to tool wear, shaking, and surface finish.
6061 makeup and common tempersYield strength and easy machining linksHeat passing and heat flowChip making and chip thicknessTemper effect on burrs and finishLeft stresses and part bendingLesson 6Tool life estimation and monitoring methods for batch productionThis part shows ways to guess and watch tool life in batch making. You will use wear rules, Taylor equations, counters, and during-work signals to plan tool changes and avoid waste or big breaks.
Tool wear kinds and break waysSetting end-of-life wear rulesBasic Taylor tool life equation useUsing part and time countersSpindle load and shake watchingTool life following 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 details tool kinds and sizes for pocketing and holemaking in 6061. You will compare face mills, end mills, slotters, drills, ring cutters, and helical turning, focusing on strongness, chip taking out, and time per cycle.
Face mill sizing for surfacing 6061Flat end mills for pockets and slotsHigh-feed and slotting plansTwist drills against ring cuttersHelical turning for exact holesTool length and strongness pickLesson 8Tool geometry for aluminium: helix angle, rake, margin, polished flutes to prevent BUEThis part explains cutter shape features that better aluminium machining. You will learn how helix angle, rake, margin width, and polished flutes change cutting forces, chip taking out, and fight against built-up edge in 6061.
High rake angle for free cuttingHelix angle picks for 6061Margin width and tool guidingPolished flutes and chip taking outCorner prep and edge hone sizeShape to cut built-up edgeLesson 9Climb vs conventional milling in aluminium: advantages, when to use eachYou will compare climb and usual milling plans in aluminium 6061. The part explains chip thickness shapes, tool bending, backlash worries, and when each way is better for roughing, finishing, and thin-wall parts.
Chip thickness in climb vs usualBacklash and machine state limitsRoughing plan pick in 6061Finishing runs and wall steadyTool bending and size errorEntry, exit, and holding effectsLesson 10Typical feed, speed, and depth-of-cut ranges for roughing and finishing aluminium 6061 (tabulated for common tool diameters)This part sets real starting feeds, speeds, and cut depths for roughing and finishing 6061. You will compare ranges by tool size, job type, and machine strongness, then learn safe changes from table values.
Roughing vs finishing setting goalsTabled ranges by tool sizeChanging for spindle power and strongnessEffect of side vs depth joiningChip load per tooth and feed mathScaling values for small and big tools
