Aluminum (automotive)

How to use the tool

Selection mode: select operation, alloy, tool type, cooling type and priority. The tool will check the compatibility of parameters, display a risk checklist and give specific recommendations.

“Diagnostics” mode: click on the symptom (build-up, burr, vibration, etc.), specify the speed and type of alloy - get the cause and solution.

Features of aluminum processing in the automotive industry

Aluminum alloys make up 40–60% of the mass of a modern automobile engine, transmission and chassis. Their machinability appears simple, but typical problems—built-up edge (BUE), galling, and chip clogging—result in significant scrap rates.

Wrought alloys 6xxx (6061, 6082) and 7xxx (7075): Tough, sticky. The main enemy is the build-up on the cutting edge (Built-Up Edge). Occurs with low Vc, poor coolant or continuous contact. Solution: polished rake face (Ra < 0.4 µm), rake angle ≥ 15°, Vc > 300 m/min, DLC or ZrN coating.

Al-Si casting alloys (ADC12, A380, AK12): With Si ≥ 9% - highly abrasive material. Solid Si particles destroy the edge of the solid. rafting in minutes. The only correct choice for mass production is PCD (polycrystalline diamond) or CVD diamond coating. The service life of PCD is 5–20 times higher than that of carbide.

Diagnosis of common problems

Built Up/Adhesion (BUE): Increase Vc, apply DLC coating or polished edge, improve coolant targeting. Continuous feed without stopping in the cut.

Burr at exit: sharp edge without radius, down-milling, tool exit at an angle. Check spindle runout (< 3 µm).

Poor roughness Ra: spindle runout is the main cause in 70% of cases. Reduce fz, Vc ≥ 200 m/min, polished edge, stable feed without stopping.

Chip clogging (especially drilling): ≤ 3 teeth/flutes - better for Al. Peck cycle at L/D > 3. Coolant pressure up. At L/D > 5 - internal cooling.

Vibrations: reduce overhang, increase fz (contact → less tendency to vibration), down milling.

Frequently Asked Questions

Can Al be machined dry? Only with specialized DLC-coated cutters with wide chip flutes. In general, there is a critical risk of build-up and scuffing. Flood or MQL are required.

HSS or carbide for Al-HSS is suitable for single jobs at low Vc (≤ 80 m/min). For the series - polished TV. alloy or PCD.

What does thermal expansion mean for precise tolerances? Al expands twice as much as steel (23 µm/m °C). With tolerances H7 and more precisely, cooling is mandatory; the temperature of the part and the tool must be stabilized.

Selection of PCD and TV tools. alloy for processing aluminum - our specialists will help you create a kit.