The Core Challenges of High-Speed Machining of Aluminum Alloy
Aluminum alloys exhibit significant plasticity, leading to chip adhesion during high-speed cutting. This exacerbates tool edge wear and compromises surface quality. High-speed rotation induces vibration issues, reducing both machining accuracy and tool life. Under large-depth cutting conditions, traditional tools struggle to balance heat dissipation and edge integrity. Taking high-strength aluminum alloy A7075 as an example: during high-speed cutting (linear speed exceeding 1000 m/min), traditional tool coatings are prone to failure. Additionally, inadequate helical flute designs can trigger high-frequency vibrations, limiting efficiency improvements.
Technical Innovations in the New Generation AL-HSM High-Speed Milling Cutter
Optimized Geometric Edge Design:
Features a low helix angle design to reduce cutting resistance and friction area, minimizing chip adhesion. Optimized cutting angles, combined with precisely ground center cutting edges, balance edge sharpness and strength. Ensures stable cutting even at large depths of cut (ap up to 0.75×Diameter).
DLC Coating Technology Application:
Diamond-Like Carbon (DLC) coating boasts a hardness exceeding 2000 HV and an ultra-low friction coefficient of 0.1~0.2, effectively eliminating chip adhesion. Its excellent high-temperature stability maintains superior wear resistance at cutting speeds above 1200 m/min, significantly extending tool life.
Variable Pitch & Variable Lead Structure:
Incorporates variable pitch tooth spacing and variable lead flute design to disperse vibrational energy and prevent resonance. Guarantees stable cutting performance during high-feed-rate machining.
A7075 High-Strength Aluminum Alloy Machining Case
Groove Cutting
Tool Used: φ20R3
Tool Overhang Length: 65mm
Spindle Speed: n = 20,000 rpm
Cutting Speed: Vc = 1,257 m/min
Feed Rate: Vf = 15,151 mm/min
Feed per Revolution: f = 0.76 mm/rev
Depth of Cut: ap = 8mm (0.4D)
Width of Cut: ae = 20mm
Machining Result: High-speed stable cutting with no visible material buildup on the cutting edge. Compared to conventional tools, the feed rate increased by 50% under identical parameters, significantly improving efficiency.
Shoulder Milling
Tool: Ø20R3
Overhang: 65 mm
Spindle Speed (n): 20,000 RPM
Cutting Speed (Vc): 1,257 m/min
Feed Rate (Vf): 15,151 mm/min
Feed per Rev (f): 0.76 mm/rev
Depth of Cut (ap): 15 mm (0.75D)
Width of Cut (ae): 12 mm
Machining Results:
Tool: AL-HSM High-Speed Aluminum Alloy Milling Cutter (New)
↓72% Axial Force vs. peer tools
Depth of Cut (ap): 3/4×D
Material Removal Rate (MRR): 180 cm³/min
Process: High-Efficiency Square Shoulder Milling
Vibration: None (High-Speed Cutting)
Issue Resolution:
Poor Surface Finish ×
Cutting Edge Chipping ×
