Thin Wall Techniques in Aluminum

Tips and Tricks for Thin Wall Machining:

• Use short length of cut tools for minimum wall contact
• Necked tools extend reach, but choose the most rigid
• Climb mill
• Leave 0.100″ of material on walls for stability when finishing
• Finish the part at every Z-level

Tools for Thin Wall Aluminum Parts

• Mirror Edge geometry tools dampen the cut to reduce chatter
  • Great for plunging corners in titanium, steels, stainless, aluminum, etc.
  • Deep pockets and thin walls in aluminum
  • Long reaches more than 3:1 length to diameter
  • MUST USE COOLANT!!
• Feather Blend tools have a smooth transition between cutting and neck diameters, which reduces “ledging”
  • May be added to any necked tool
  • Eliminates swirl lines during plunging
  • Eliminates stress risers in parts

FM Series End Mills

• Features
  • High radial rake
  • More room for chips
  • Small chamfer to protect corner
  • Polished flutes
  • Mirror edge to reduce chatter
• Applications
  • Recommended for profiling (New CAD/CAM)
  • Must use coolant
  • Aluminum
  • Copper
  • Brass