G-Wizard Calculator:
Fast, Easy, Reliable Feeds and Speeds


Join 100,000+ CNC'ers!  Get our latest blog posts delivered straight to your email inbox once a week for free. Plus, we’ll give you access to some great CNC reference materials including:

  • Our Big List of over 200 CNC Tips and Techniques
  • Our Free GCode Programming Basics Course
  • And more!


GCode is Complicated
G-Wizard Makes it Easy

Avoid aluminum welding into end mill


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.

  • You must to post comments

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.

  • You must to post comments

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.

  • You must to post comments

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.

  • You must to post comments
Showing 3 results
Your Answer
Post as a guest by filling out the fields below or if you already have an account.
Show us your humanity*


Do you want to be a better CNC'er in 37 Seconds?

Get Better Tool Life, Surface Finish, and Material Removal Rates Fast.

It's that easy. You can install and get results in a matter of minutes.


Start Now, It's Free!



  GW Calculator

  GW Editor



  Deals and Steals

CNC Blog








     Feeds and Speeds

     G-Code Tutorial

     CNC Machining & Manufacturing

     DIY CNC Cookbook

     CNC Dictionary

CNC Projects


     Machinist's Search


     Online Groups


     Reference Data


     CNC Dictionary


     Tool Brands


     Hall of Fame

     Organization: Soon!





     Our History

     Privacy Policy

All material © 2016, CNCCookbook, Inc.