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Spindle-mounted cutter milling a metal workpiece

Aluminum Milling

Choose an end mill for aluminum around the alloy, the feature and the way chips leave the cut. MSU offers MAE3, MAU3 and MAE3-plus three-flute flat-end tools.

Compare flute geometry and working dimensions before selecting a size. For a deep pocket or long sidewall, check the cutting length and holder clearance as well as the diameter.

Send the alloy and feature drawing, or a full model code and quantity for a quote.

Find an Aluminum Milling Tool

Match the Aluminum Alloy and Machining Task

Wrought and cast aluminum, aging condition and silicon content distinguish the material rows below. Use the alloy specification to select the relevant group.

Four aluminum milling cutters with different flute finishes
  • Open side or enclosed slot Identify how much of the tool is engaged and where the chips can leave the feature.
  • Pocket depth Allow enough cutting edge for the planned cut and enough body and holder clearance to reach it.
  • Floor and corner Match the cutting profile and corner detail to the required part geometry.
  • Chip removal Check that the coolant or air delivery reaches the cut and that chips can leave rather than remain in the toolpath.

For a different flute count, compare Single-Flute End Mills against the alloy and operation. Select its cutting conditions separately from the three-flute options below.

Compare the flute geometry and available lengths for your cut.

Compare Aluminum Milling Tools

MAE3-plus Starting Cutting Conditions

Use the row matching the aluminum stock and condition. The table is for shoulder milling, not a full-width slot or a different tool family.

Milling cutter producing curled chips in a metal workpiece

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

D is cutter diameter, Ap axial depth and Ae radial width of cut. Vc is cutting speed in m/min and fz is feed per tooth in mm/tooth. These values apply to MAE3-plus with the listed aluminum conditions. Check the selected model and setup in a trial; do not transfer the values to MAE3, MAU3 or copper machining.

The End Mill Selection Guide covers geometry and setup; the End Mill Coating Guide and End Mill Flute Count Guide explain coating and flute-count choices.

For a chip or surface-finish problem, send the alloy, tool reference and current cutting conditions.

Discuss Your Aluminum Milling Job

Check Clearance and the Machined Result

A cutter that fits the feature still needs clearance for its body and holder, and a path for chips to leave.

MSU facilities and inspection equipment

Access to the cut

Check the chuck and tool body at the deepest position, not only at the top of the feature.

Coating and dimensions

Specify the coating or uncoated option for the full model. Match the cutting length, shank and overall length to the mounted setup.

Compare trial results

Compare the finished surface and dimensions alongside tool wear and chip evacuation. Keep the alloy condition and cutting settings with the result.

Tool drawings and measurement

Find model drawings in Downloads. For inspection equipment and measurement information, see Factory and Quality Control. State any required tool reports before ordering.

Use the model drawing to check the full dimensions before ordering.

Find Tool Drawings

Order a Standard Tool or Discuss a Drawing

Choose a standard model when its profile and working dimensions fit the part. For an unavailable size or clearance, a drawing defines what needs to change.

MSU cutting tools

Standard sizes

Specify the full MAE3, MAU3 or MAE3-plus model, required coating option and quantity. A family name alone does not identify the size.

A tool to your drawing

For a different reach, cutting profile or clearance, email the dimensioned feature for Custom Cutting Tools, with the aluminum alloy and operation. See Ordering and Delivery for purchasing terms.

MSU cutting tools

Email the drawing with the material and critical dimensions to discuss the tool you need.

Discuss a Custom Tool

Aluminum Milling Questions

What is different about MAE3-plus?

MAE3-plus uses a 37°/39°/41° unequal helix; MAE3 and MAU3 use a 45° helix. Compare the complete model dimensions and cutting conditions as well as the flute geometry.

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

No. The table is specific to MAE3-plus shoulder milling at Ap = 2.5 D and Ae = 0.15 D. Select separate starting conditions for MAE3 or MAU3.

Is fz the same as the machine table feed?

No. fz is the feed per tooth. Table feed also depends on spindle speed and the number of cutting teeth; do not enter the fz value as a table-feed setting.

What should I compare if chips remain in a pocket?

Check the chip exit path, flute space, tool engagement and coolant or air delivery. Keep the alloy, tool dimensions and current speed and feed together when requesting application help.