Aluminum Sheet Cutting

My actual cutting parameters for aluminum sheet:

• Material: 1100 aluminum (I’ve cut 1mm and 2.5mm sheets)
• Feed: 600mm-min or 24IPM (I’ve used 800mm-min, but now I’m being conservative)
• End-mill: 4-flute 1.5mm carbide. I’ve used 2-flute and 3-flute; the more flutes, the more quiet the cut.
• DOC: 0.2mm
• Spindle speed: max (2800 rpm)
• Lubricant: some WD40
• Finish pass required.

A lot of peoples says 1100 is a nightmare to machine, but as always, you just need to know it. I settle in these parameters by a test-error process, but I don’t now if these are the optimal ones. I just know these values work for me. And of course these small carbide end-mill would enjoy more rpm.

For 5052 I’ve used the same parameters, but you need to lower the feed a bit; a friend broke some end-mills at 800mm-min because of my speed thirst (nevertheless that was fun).

One last thing… the part in the photos is 2.5mm thick, so it was strong enough to withstand all the cutting with just a few screws. If that were a 1mm sheet more screws would be required.