Aluminum Milling Speed Chart
This page targets aluminum surface speed, aluminum milling speed chart, and aluminum end mill feed questions. It separates cast/wrought aluminum carbide data from diamond end mill guidance for high-silicon aluminum.
Aluminum surface speed and chip-load table
| Material | Group | SFM | 1/8" | 3/16" | 1/4" | 3/8" | 1/2" | 5/8" | 3/4" | 1" |
|---|---|---|---|---|---|---|---|---|---|---|
| Aluminum 440/356/380/C61300 | Cast aluminum / aluminum bronze family | 500-1000 | 0.001 | 0.002 | 0.002 | 0.003 | 0.004 | 0.005 | 0.006 | 0.007 |
| Aluminum 2024/6061/7075 | Wrought aluminum alloys | 800-1500 | 0.001 | 0.002 | 0.002 | 0.003 | 0.004 | 0.005 | 0.006 | 0.007 |
| Aluminum 5%-8% Si with diamond end mill | Non-ferrous / diamond tooling | 2000-6000 | 0.005-0.010 | — | — | — | — | — | — | — |
| Aluminum 8%-12% Si with diamond end mill | Non-ferrous / diamond tooling | 1500-5000 | 0.004-0.008 | — | — | — | — | — | — | — |
| Aluminum 14%-18% Si with diamond end mill | Non-ferrous / diamond tooling | 1000-3000 | 0.002-0.006 | — | — | — | — | — | — | — |
End mill RPM and feed calculator
Aluminum milling notes
Aluminum often allows high surface speed, but chip evacuation, flute polish, coating choice, and built-up edge control are critical. Use fewer flutes when chip evacuation is limited and consider coolant or air blast.
FAQ
Are these chart values final production recommendations?
No. They are starting values for planning. Use the specific cutting tool manufacturer data, workholding condition, coolant method, and machine limits before running production parts.
Why do different speed and feed charts disagree?
Charts assume different tool materials, coatings, tool life targets, rigidity, coolant, radial engagement, and material hardness. A generic chart should be adjusted to the actual tool and setup.
What surface speed should I use for 6061 aluminum milling?
For a carbide end mill, a published general starting range for 6061-T6/T651 is 800–1500 SFM. Use the low end for conservative setups and adjust after checking chips, finish, spindle load, and tool wear.
Why can diamond tools run faster in aluminum?
Diamond tooling is used for non-ferrous abrasive materials and can support much higher surface speeds, but it is not a universal replacement for carbide and should be matched to the material and machine.
Data sources and limits
These charts are starting values only. Actual speeds and feeds depend on tool geometry, coating, holder rigidity, coolant, chip evacuation, radial width of cut, axial depth of cut, material hardness, and machine power.
- Sandvik Coromant: milling definitions for cutting speed, spindle speed, feed per tooth, feed per minute, MRR, cutting force, and power.
- Kennametal: RPM, IPM, chip-load, and SFM formulas.
- Harvey Tool: general carbide end mill SFM and chip-load tables.
- Norseman Drill & Tool: HSS drill speed and feed rules of thumb.
- LittleMachineShop: turning, milling, drilling, and reaming cutting speed tables.