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Avoid aluminum welding into end mill

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Is there a way to avoid this? Like, what is the main cause for this problem, is it a high feed? excesive amount of chips? cutter worn off? lack of refrigerant or high temps?

I have this problem cutting a wide part of aluminum and it’s driving me crazy. Even using G-wizard calculator.

Thanks in advance for the help.

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It’s almost always due to lack of lubricant.  Aluminum needs some kind of lubricant either from mist or flood coolant.  You can get by without it by taking extremely shallow cuts and working hard to get the chips out of the cut before the cutter can encounter them.  It is typically chips already cut that weld on.  However, the best approach is to provide lubricant.

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A shot of WD40 on the cutter every so often works great for me.  Obviously, not really suitable for production quantities.  But if you don’t have a coolant system, it’s a good option.

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Use a coating specially designed for milling aluminum like ZRN. It helps to keep the aluminum from sticking. Also tune slightly down from whatever the calculator gives you. The calculator will assume you are using coolant and base it’s feed and speed on it.

  • Beazleybub answered 1 year ago
  • last edited 1 year ago
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