Reference Chart
Aluminum Feeds & Speeds Chart
Conservative shop-floor milling reference for 6061-T6, 7075-T651, 2024, Mic-6, and cast aluminum. Use it as a first-pass SFM and chip-load chart before validating cutter, flute, engagement, coolant, and chip evacuation.
Reviewed: 2026-04-23Source: Reviewed against ISO 230, GB/T 17421, OEM documentation, and shop-floor calculator assumptions.
Direct answer: use roughly 800-1,500 SFM as the conservative carbide start for wrought aluminum. Treat 6061-T6, 7075-T651, 2024, Mic-6, and cast aluminum rows as first-pass chart values; move above that range only when the cutter family, radial engagement, coolant strategy, and machine RPM support HEM/HSM.
Material chart
Aluminum Feeds and Speeds Reference
Conservative first-pass SFM and chip-load ranges for common aluminum alloys before setup-specific calculator validation.
| Alloy / condition | Starting SFM | Chip load window | Release note |
|---|---|---|---|
| 6061-T6 milling | 800 - 1,500 SFM | 0.004 - 0.008 IPT on 1/2 in end mill | Watch built-up edge and chip evacuation. |
| 6061-T6 finishing | 1,000 - 1,800 SFM | 0.001 - 0.003 IPT | Use sharp polished or ZrN tooling and validate HEM/HSM before going faster. |
| 7075-T651 roughing | 700 - 1,300 SFM | 0.005 - 0.009 IPT | Harder aerospace plate needs rigidity and temper validation. |
| 2024 aluminum | 700 - 1,200 SFM | 0.003 - 0.006 IPT | Use coolant or MQL to manage adhesion. |
| Cast aluminum / Mic-6 | 800 - 1,500 SFM | 0.003 - 0.007 IPT | High silicon castings can be abrasive. |
| Aluminum drilling handoff | 300 - 600 SFM by drill material | 0.002 - 0.012 IPR by diameter | Use drilling calculator for pecking and depth. |
Download / export next steps
Download aluminum reference PDF
Export the summarized alloy, SFM, chip-load, and handoff table for setup review.
Validate Aluminum Milling Setup Values
Use this chart for a fast first pass. Then move to the aluminum calculator when flute count, coating, stepover, chip evacuation, or built-up-edge risk need a setup-specific answer.
Reference handoff
Aluminum table handoff
Use this chart as the aluminum reference, then route setup-specific milling, chip-load, or drilling checks into calculators.
Best starting point
Reference SFM and chip-load ranges for aluminum milling families.
Branch when
Drilling, turning, and cutter-specific release need calculator validation.
6061-T6 (General Purpose)
The most common aluminum alloy. Gummy but machines well. Requires high RPM and sharp tools (ZrN or Uncoated).
| Tool Material | Operation | SFM Range | Chip Load (1/2" End Mill) |
|---|---|---|---|
| Carbide (Uncoated/ZrN) | Roughing | 800 - 1500 | 0.004" - 0.008" |
| Carbide (Uncoated/ZrN) | Finishing | 1000 - 1800 | 0.001" - 0.003" |
| Carbide (Uncoated/ZrN) | Slotting (100% WOC) | 700 - 1200 | 0.003" - 0.005" |
| HSS (High Speed Steel) | General Milling | 400 - 800 | 0.002" - 0.004" |
7075-T651 (High Strength / Aerospace Plate)
Harder and stronger than 6061. Aerospace plate is often purchased as 7075-T651, so treat the chart as a conservative start before supplier, temper, and setup validation.
| Tool Material | Operation | SFM Range | Chip Load (1/2" End Mill) |
|---|---|---|---|
| Carbide (Uncoated/ZrN) | Roughing | 700 - 1300 | 0.005" - 0.009" |
| Carbide (Uncoated/ZrN) | Finishing | 900 - 1500 | 0.001" - 0.003" |
| Carbide (Uncoated/ZrN) | Slotting | 600 - 1000 | 0.003" - 0.006" |
2024 & Cast Aluminum (Mic-6)
2024 (Copper Alloy)
Tougher than 6061 and usually more adhesion-prone than 7075. Watch chip evacuation and coolant quality.
| SFM | 700 - 1200 |
| Notes | Use Coolant! |
Cast Al (Mic-6 / A356)
Often cleaner-cutting than soft wrought grades, but high-silicon castings are abrasive and can punish the wrong tool fast.
| SFM | 800 - 1500 |
| Tooling | Carbide Only |
If The Job Is Drilling, Switch Workflows
This chart page is mainly for aluminum milling reference. Use the table below only as a quick drill-speed sense check, then move to the dedicated drilling calculator for peck depth, hole depth, and feed-per-rev validation.
| Drill Size | HSS RPM (300 SFM) | Carbide RPM (600 SFM) | Feed (IPR) | Peck Cycle |
|---|---|---|---|---|
| 1/8" (0.125) | 9,100 | 18,300 | 0.002 - 0.004 | Required > 3xD |
| 1/4" (0.250) | 4,500 | 9,100 | 0.004 - 0.008 | Required > 3xD |
| 3/8" (0.375) | 3,000 | 6,100 | 0.006 - 0.010 | Recommended |
| 1/2" (0.500) | 2,200 | 4,500 | 0.008 - 0.012 | Standard |
Coating Guide: What Color Should Your End Mill Be?
ZrN (Zirconium Nitride)
Color: Gold / Pale Yellow
Best for Aluminum
Excellent lubricity, prevents built-up edge.
Uncoated (Polished)
Color: Silver / Shiny
Excellent
Sharpest edge possible. Great for finishing plastics & Al.
AlTiN / TiAlN
Color: Dark Grey / Purple
DO NOT USE
Contains Aluminum. Will chemically bond to material (gall).
A Note on Cooling
The real rule is not “always flood coolant.” The real rule is never let chips stay in the cut.Soft wrought grades may need MQL or flood coolant to control built-up edge, while harder alloys can often run well with strong air blast. If chips stop clearing, the flute packs and the tool usually fails before the formula does.
Frequently Asked Questions
What SFM should I use for 6061-T6 aluminum with carbide?
Use this chart as a first-pass range, not a final release number. For 6061-T6 with carbide, start around 800-1,500 SFM for general milling. Move higher only when the cutter family, coolant, radial engagement, spindle RPM, and chip evacuation support HEM/HSM.
What is the recommended chip load for milling aluminum?
For a quick chart lookup, typical milling chip loads are about 0.002–0.004 IPT on a 1/4-inch tool and 0.003–0.006 IPT on a 1/2-inch tool. Treat those as reference windows only, because coating, flute count, alloy, and slotting versus side milling will all move the safe answer.
How do speeds differ between 6061-T6 and 7075-T651 aluminum?
7075-T651 plate is harder than 6061-T6, so use a lower conservative start. For roughing, keep 7075-T651 around 700-1,300 SFM and 6061-T6 around 800-1,500 SFM before cutter-specific validation.
Should I use flood coolant or mist for aluminum?
Use the method that keeps chips out of the cut. Flood coolant, MQL, mist, or strong air blast can work depending on alloy, tool coating, enclosure, and finish target; if chips pack in the flutes, reduce the setup before raising SFM.
What are the best tool coatings for aluminum?
Uncoated polished carbide or ZrN coating. ZrN resists aluminum adhesion. Avoid TiAlN and AlTiN — the aluminum content causes welding/galling.