Luminum

Machining Guide For
Aluminum Rod & Bar



The tables below provide general guidance for the layout and machining of the most popular rod and bar alloys.

Turning — Box tools, knee and hollow mills

Alloy Depth of Cut
(Inches)
Surface FPM Feed
In/Rev
Multi Spindle Single Spindle
2011-T3 1/8 600 600 - 1100 .012
1/4 .010
3/8 .008
2024-T351 1/8 300 - 550 300 - 550 .010
1/4 .008
3/8 .006
6061-T651
6061-T6511
7075-T651
1/8 300 - 550 300 - 550 .008
1/4 .006
3/8 .006

Forming — Circular, flat or dovetail

Alloy Width of Cut
(Inches)
Surface FPM Feed
In/Rev
Multi Spindle Single Spindle
2011-T3 1/8 - 1/4 600 - 800 700 - 1100 .0035
1/4 - 1/2 .0030
1/2 - 3/4 500 - 600 .0025
3/4 - 1 .0020
1 - 1-1/2 .0015
2024-T351 1/8 - 1/4 450 - 550 .0030
1/4 - 1/2 .0025
1/2 - 3/4 .0015
3/4 - 1 .0010
6061-T651
6061-T6511
7075-T651
1/8 - 1/4 300 - 450 .002
1/4 - 1/2 .002
1/2 - 3/4 .001
3/4 - 1 .001

Shaving

Alloy Depth of Cut
(Inches)
Surface FPM Feed
In/Rev
Multi Spindle Single Spindle
2011-T3 .005 700 - 1100 .003
.010 .002
.015 .001
2024-T351 .005 450 - 550 .0025
.010 .010
.015 .005
6061-T651
6061-T6511
7075-T651
.005 300 - 450 .0015
.010 .0010
.015 .0005

Twist Drilling — Standard and fast spiral

Alloy Diameter
(Inches)
Surface FPM Feed
In/Rev
Multi Spindle Single Spindle
2011-T3 1/32 400 600 .002
1/16 .004
1/8 .009
1/4 .014
3/8 .016
1/2 .016
3/4 .016
1 550 .016
1-1/4 .016
1-1/2 .016
1-3/4 450 .016
2 .016
2024-T351 1/32 350 500 .002
1/16 .004
1/8 .008
1/4 .011
3/8 .013
1/2 .013
3/4 .013
1 .013
1-1/4 .013
1-1/2 .013
1-3/4 450 .013
2 .013
6061-T651
6061-T6511
7075-T651
1/32 300 .0015
1/16 .0030
1/8 .0050
1/4 .0070
3/8 .0090
1/2 .0100
3/4 .0100
1 .0100
1-1/4 .0100
1-1/2 .0100
1-3/4 .0100
2 .0100

Half Round Drilling

Alloy Diameter
(Inches)
Surface FPM Feed
In/Rev
Multi Spindle Single Spindle
2011-T3 3/32 - 3/8 600 .005 - .008
3/8 - 3/4 .008 - .012
3/4 - 1-1/4 550 .012 - .020
2024-T351 3/32 - 3/8 450 - 550 .004 - .007
3/8 - 3/4 .008 - .010
3/4 - 1-1/4 .012 - .014
6061-T651
6061-T6511
7075-T651
3/32 - 3/8 250 - 350 .003 - .006
3/8 - 3/4 .007 - .009
3/4 - 1-1/4 .010 - .012

Reaming

Alloy Diameter
(Inches)
Surface FPM Feed
In/Rev
Multi Spindle Single Spindle
2011-T3 - 1/8 600 - 450 .007 - .010
+ 1/8 .010 - .020
2024-T351 - 1/8 500 - 450 .007 - .010
+ 1/8 .010 - .020
6061-T651
6061-T6511
7075-T651
- 1/8 300 - 250 .007 - .010
+ 1/8 .010 - .020

Taper Reaming

Alloy Diameter
(Inches)
Surface FPM Feed
In/Rev
Multi Spindle Single Spindle
2011-T3 All Sizes 300 - 500 .002 - .005
2024-T351 All Sizes 300 - 500 .002 - .005
6061-T651
6061-T6511
7075-T651
All Sizes 300 - 450 .002 - .005

Tapping

Alloy Pitch of
Threads
Surface FPM Feed
In/Rev
Multi Spindle Single Spindle
2011-T3 3 - 8 50 - 75  
9 - 15 90 - 125  
16 - 24 125 - 150  
>= 25 150 - 200  
2024-T351 3 - 8 50 - 75  
9 - 15 90 - 125  
16 - 24 125 - 150  
>= 25 150 - 200  
6061-T651
6061-T6511
7075-T651
3 - 8 50 - 75  
9 - 15 90 - 125  
16 - 24 125 - 150  
>= 25 150 - 200  

Threading

Alloy Pitch of
Threads
Surface FPM Feed
In/Rev
Multi Spindle Single Spindle
2011-T3 3 - 8 200  
9 - 15 250  
16 - 20 325  
>= 21 400  
2024-T351 3 - 8 150  
9 - 15 200  
16 - 20 250  
>= 21 300  
6061-T651
6061-T6511
7075-T651
3 - 8 100  
9 - 15 150  
16 - 20 200  
>= 21 250  

Cutoff

Alloy Width of Cut
(Inches)
Surface FPM Feed
In/Rev
Multi Spindle Single Spindle
2011-T3 1/8 700 - 1100 .0035
3/16 .0040
1/4 .0040
2024-T351 1/8 450 - 550 .0030
3/16 .0035
1/4 .0040
6061-T651
6061-T6511
7075-T651
1/8 300 - 450 .0025
3/16 .0030
1/4 .0040

Turret Knurling — 1/4 inch width knurl, double feeds for knurl back off

Alloy Stock Diameter
(Inches)
Surface FPM Feed
In/Rev
Multi Spindle Single Spindle
2011-T3 1/4 700 - 1100 700 - 1100 .0125
3/8 .0145
1/2 500 - 700 .0190
3/4 .0195
1 .0205
1-1/4 .0215
2024-T351 1/4 450 - 550 .0125
3/8 .0145
1/2 .0190
3/4 .0195
1 .0205
1-1/4 .0215
6061-T651
6061-T6511
7075-T651
1/4 300 - 450 .0125
3/8 .0145
1/2 .0190
3/4 .0195
1 .0205
1-1/4 .0215

Cross Slide Knurling — 1/4 inch width knurl

Alloy Stock Diameter
(Inches)
Surface FPM Feed
In/Rev
Multi Spindle Single Spindle
2011-T3 1/4 700 - 1100 700 - 1100 .0025
3/8 .0033
1/2 500 - 700 .0045
3/4 .0060
1 .0075
1-1/4 .00095
2024-T351 1/4 450 - 550 .0025
3/8 .0033
1/2 .0045
3/4 .0060
1 .0075
1-1/4 .00095
6061-T651
6061-T6511
7075-T651
1/4 300 - 450 .0025
3/8 .0033
1/2 .0045
3/4 .0060
1 .0075
1-1/4 .00095

Counterboring and Trepanning

Alloy Width of Cut
(Inches)
Surface FPM Feed
In/Rev
Multi Spindle Single Spindle
2011-T3 3/8 700 - 800 700 - 1100 .0050
1/2 .0075
3/4 500 - 700 .0090
1 .0100
1-1/4 .0110
2024-T351 3/8 450 - 550 .0040
1/2 .0050
3/4 .0060
1 .0075
1-1/4 .0090
6061-T651
6061-T6511
7075-T651
3/8 300 - 450 .003
1/2 .004
3/4 .005
1 .006
1-1/4 .007

Thread Rolling — Cross slide tools

Speed of rolls is determining factor.  Check with thread roll vendor.

Alloy Tool Surface FPM Spindle
Rev
Multi Spindle Single Spindle
2011-T3 <= 9 pitch 500 - 600 20 - 29
9 - 14 pitch 13 - 24
14 - 18 pitch 12 - 22
>= 18 pitch 10 - 18
2024-T351 <= 9 pitch 500 - 600 20 - 29
9 - 14 pitch 13 - 24
14 - 18 pitch 12 - 22
>= 18 pitch 10 - 18
6061-T651
6061-T6511
7075-T651
<= 9 pitch 500 - 600 20 - 29
9 - 14 pitch 13 - 24
14 - 18 pitch 12 - 22
>= 18 pitch 10 - 18

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