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Aluminum Material and Application Review

Aluminum Milling

Choose an end mill for aluminum by alloy, operation and machine conditions. Compare the MSU MA, MAU and MA-plus families, then select the exact product and starting conditions for your application.

For carbide end mills for aluminum, send the workpiece grade, feature, tool dimensions, machine and chip-evacuation conditions together. The exact product code and operating starting point remain subject to application review.

Send the aluminum grade and machining conditions for a product-family review.

Request an Aluminum Milling Review

Define Your Requirement

An aluminum milling requirement is more useful when it identifies the material and the cut rather than only saying aluminum. Send the alloy or material specification, whether the stock is wrought or cast, and any relevant condition such as age hardening. Include the feature, toolpath, roughing or finishing intent, target diameter, required reach and quantity.

Temporary visual for the aluminum milling requirement workbench
  • Material Alloy or material specification, wrought or cast stock and any relevant condition such as age hardening.
  • Operation Feature, toolpath and roughing or finishing intent.
  • Tool requirement Target diameter, required reach, flute length, shank and quantity.
  • Machine setup Machine, spindle, holder, overhang and workholding.
  • Fluid and air Coolant or air method and delivery conditions.
  • Chip evacuation How chips must leave the cut and any current chip-control issue.

Single-flute aluminum applications need engineering review of the tool and cut. Router-bit, wood and plastic requirements must be assessed separately from these aluminum end-mill families.

Use these details to select a catalog tool, specify the required geometry or prepare a custom inquiry. Aluminum alloy and machine conditions must be considered together.

Map the material and operation before comparing the three aluminum families.

Compare Aluminum Families

Selection Factors

Start with the cut geometry and then check whether the selected family provides the required catalog fields.

  • Alloy and stock condition, including whether the material is wrought or cast.
  • Shoulder, profile, slotting or another defined operation.
  • Target diameter, reach, flute length and shank requirements.
  • Flute count and the chip space required by the operation.
  • Edge geometry and the coating or uncoated ordering option shown for the exact code.
  • Spindle, holder, overhang, workholding, coolant and chip-evacuation method.
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MAE3-plus only Shoulder milling Ap = 2.5 D Ae = 0.15 D

MAE3-plus Starting Values

The following values are starting points for MAE3-plus only. They are tied to shoulder milling with Ap = 2.5 D and Ae = 0.15 D. Metric units apply. fz values are mm/tooth. Select the column matching the cutter diameter, then verify the complete tool code and setup before use.

Material and condition Hardness / reference Vc (m/min) fz Ø2 fz Ø4 fz Ø6 fz Ø8 fz Ø10 fz Ø12 fz Ø14 fz Ø16 fz Ø20
Wrought aluminum alloy, not age-hardened HB 30 380–450 0.022 0.040 0.055 0.085 0.090 0.110 0.120 0.140 0.180
Wrought aluminum alloy, age-hardened / naturally aged HB 100; tensile 340 N/mm² 320–380 0.022 0.040 0.055 0.065 0.090 0.110 0.120 0.140 0.160
Cast aluminum alloy, ≤12% Si, not age-hardened HB 75; tensile 260 N/mm² 260–300 0.022 0.040 0.055 0.065 0.090 0.110 0.120 0.140 0.160
Cast aluminum alloy, ≤12% Si, age-hardened / naturally aged HB 90; tensile 310 N/mm² 260–300 0.022 0.040 0.055 0.065 0.090 0.110 0.120 0.140 0.160
Cast aluminum alloy, >12% Si, not age-hardened HB 130; tensile 450 N/mm² 250–290 0.019 0.034 0.047 0.055 0.077 0.094 0.102 0.119 0.136

Use these MAE3-plus values as starting points for the listed aluminum conditions. Confirm the alloy, material condition, diameter, engagement, tool geometry, machine, holder, overhang, workholding, coolant and chip evacuation. Begin conservatively and validate the result in your setup. MAE3, MAU3, copper and other end forms require separate starting conditions.

For broader selection context, review the End Mill Selection Guide, End Mill Coating Guide and End Mill Flute Count Guide.

Send the exact alloy and setup before applying a series-level starting value to a specific tool.

Ask for Selection Support

Catalog and Application Requirements

The end-mill catalog lists the MA, MAU and MA-plus families. The starting table applies only to MAE3-plus under the stated shoulder-milling conditions.

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Catalog scope

Catalog records support family-level product identification. The complete code, diameter, reach, coating and ordering fields still need to be checked for the requested tool.

Parameter scope

Use the MAE3-plus starting values with the listed material category, diameter, Ap and Ae. Select separate starting conditions for MAE3, MAU3, copper or another end form.

Application limits

Assess tool life, cycle time, finish, accuracy and chip control using the exact tool and machining setup. Include the coating, flute geometry and any current tool or result you want to compare in your inquiry.

Verification route

Use Downloads to check the catalog and complete code. Factory provides manufacturing information for MSU carbide end mills, while Quality Control covers inspection requirements and document requests.

Verify the catalog information and keep the operating conditions attached to every selection.

View End Mill Catalogs

Standard or Custom Options

Compare catalog geometry and dimensions with your aluminum application, or send the drawing for custom engineering review.

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Standard catalog route

Use a standard catalog route when the required end form, diameter, reach, flute length, shank and ordering fields match a current code. Include the complete code and quantity in the inquiry. Do not order from a family label alone.

Custom engineering route

Use Custom Cutting Tools if the required geometry, dimensions, substrate or coating differs from the catalog. MSU assesses material, geometry, tolerance and coating together before confirming feasibility. See Ordering and Delivery for commercial terms.

Temporary visual for the custom aluminum cutting tool route

Use the custom route when the catalog geometry or ordering fields do not match the aluminum application.

Review Custom Cutting Tools

Aluminum Milling Questions

Which materials can I submit for tool selection?

Compare aluminum and non-ferrous milling requirements within the MA, MAU and MA-plus family range. Send the exact alloy and condition for selection.

Which MSU families are mapped to aluminum milling?

MA / MAE3, MAU / MAU3 and MA-plus / MAE3-plus. The exact code, geometry and ordering fields must still be checked.

Can I use the MAE3-plus values for MAE3 or MAU3?

No. These are MAE3-plus series-level starting values. MAE3 and MAU3 require their own parameter selection.

What operation do the displayed starting rows describe?

They describe shoulder milling with Ap = 2.5 D and Ae = 0.15 D. Confirm the operation and engagement before using them.

Are the values guaranteed for every aluminum alloy?

No. They are starting points for the listed material categories and conditions. Verify the actual alloy, setup and tool code.

Can I use these families for router-bit or woodworking requirements?

These families are for MSU aluminum end-mill selection. Router-bit, wood and plastic requirements need separate product and application review.

Can MSU review a single-flute or custom aluminum requirement?

Yes, as an engineering review request. Send the drawing or tool details, alloy, operation, machine, chip-evacuation conditions and quantity.