Machining deep cavities in aluminium

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Lyn Stewart

29.11.2024 at 11:35

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Hi all, I’m machining 60 mm deep, 20 mm diameter cavities in Aluminum 6061 with ±0.05 mm tolerances. Issues like chatter, tool deflection, and poor chip evacuation make it tricky, and I’m concerned about overheating and tool wear. Do you have any advice on tool selection, speeds/feeds, cooling, or strategies to balance precision and efficiency?

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• • L

    Lyn Stewart

    29.11.2024 at 11:35

    Hi all, I’m machining 60 mm deep, 20 mm diameter cavities in Aluminum 6061 with ±0.05 mm tolerances. Issues like chatter, tool deflection, and poor chip evacuation make it tricky, and I’m concerned about overheating and tool wear. Do you have any advice on tool selection, speeds/feeds, cooling, or strategies to balance precision and efficiency?

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    J Kalberg

    29.11.2024 at 14:09

    That’s a challenging need – 60 mm depth at ±0.05 mm tolerance is pushing it, especially allowing for chatter and tool deflection. First, the depth-to-diameter ratio is 3:1, which is on the edge of manageable, beyond ideal. With higher aspect ratio cavities, precision is harder, and machining time and tooling costs rise. Can you split the machining into multiple stages to reduce the effective depth per pass?

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      Lyn Stewart

      02.12.2024 at 16:12

      J Kalberg

      That’s a good approach. What tools would you recommend for moderating deflection and chatter at that depth? How about speeds, feeds, and cooling?

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