Aluminum alloys like 6061 and 7075 machine fast and clean. The limiting factor is usually chip evacuation and built-up edge, not hardness, so high surface speeds with sharp tools work best.
Convert SFM to RPM: RPM = (SFM × 3.82) / cutter diameter (in). Then feed rate (IPM) = RPM × chip load × flutes. Do it instantly with the Feeds & Speeds calculators.
Cutting speeds (SFM)
| Operation | HSS (SFM) | Carbide (SFM) |
|---|---|---|
| Milling | 250 – 300 | 600 – 1200 |
| Turning | 300 – 400 | 500 – 1000 |
| Drilling | 200 – 300 | 400 – 600 |
Recommended chip load
| End mill diameter | Chip load (in/tooth) |
|---|---|
| 1/8 in | 0.0010 – 0.0020 |
| 1/4 in | 0.0020 – 0.0040 |
| 3/8 in | 0.0030 – 0.0050 |
| 1/2 in | 0.0040 – 0.0060 |
| 3/4 in | 0.0050 – 0.0080 |
| 1 in | 0.0060 – 0.0100 |
Starting points for general work. Defer to your tooling manufacturer and adjust for rigidity, coolant, depth of cut, and finish.
Tips
- Use 2–3 flute end mills so chips clear instead of packing and welding.
- Sharp, polished uncoated or ZrN / TiB2 tools resist aluminum sticking; avoid TiN.
- Climb mill and keep air blast or flood coolant on the cut to prevent built-up edge.
- If you see a dull, smeared finish, raise RPM or add coolant — that is built-up edge.
See the full Feeds and Speeds Chart for every material side by side.