Can a CNC router cut aluminium? ⚙️

Yes, a CNC router can cut aluminium, which is a soft, lightweight, and machinable metal. However, to achieve clean and precise results, it’s essential to consider several factors and make specific adjustments tailored to aluminium's properties. Here are key guidelines to follow when cutting aluminium with a CNC router:

Tool Selection

• Use a cutting tool designed for non-ferrous metals, particularly aluminium. Solid carbide end mills with two or three flutes are ideal, as they allow for better chip evacuation and prevent material from clogging the tool.

• Look for end mills with a high helix angle, as this helps remove chips quickly, keeping the cutting edge clear and ensuring smoother cuts.

Feed Rates and Spindle Speeds

• Aluminum requires a balanced approach to feed rate and spindle speed to avoid issues like melting or material buildup on the tool. Typically, use slower feed rates and higher spindle speeds compared to cutting wood.

• Finding the ideal combination may require some adjustments, as too slow a feed can cause the material to stick, while too fast can lead to tool wear or a poor surface finish.

Lubrication and Cooling

• Cooling is essential when cutting aluminium to prevent it from melting and adhering to the tool, which can damage the tool and ruin the cut.

• Compressed air or mist coolant systems are commonly used for CNC routing aluminium, as they help to reduce heat buildup, improve surface finish, and extend tool life.

Chip Evacuation

• Effective chip evacuation is crucial for aluminium machining. Use a vacuum or dust collection system to clear chips from the work area, preventing buildup around the cutting tool, which can cause clogging, poor surface finish, and tool wear.

• Regularly clearing chips also reduces heat buildup, minimizing the risk of aluminium sticking to the tool.

Rigidity and Stability

• Ensure that your CNC router has sufficient rigidity to handle the forces involved in cutting aluminium. Industrial-grade CNC routers are better suited for aluminium, as they are built to withstand these forces.

• Lightweight routers may lack the stability needed for clean cuts in aluminium, resulting in vibration, deflection, and poor cut quality. If using a lighter router, consider reducing the depth of cut and feed rate to enhance stability.

Depth of Cut and Multiple Passes

• For best results, use shallow depth cuts and make multiple passes rather than attempting a single deep cut. This approach reduces tool load, minimizes heat generation, and produces cleaner edges.

While CNC routers can handle aluminium, they are generally optimized for softer materials like wood and plastics. For extensive or high-precision aluminium work, or when working with thicker or harder aluminium grades, a CNC milling machine is a more robust choice due to its greater rigidity, power, and control over cutting parameters.

By following these guidelines and making adjustments specific to aluminium, you can achieve smooth, accurate cuts on a CNC router, expanding its capabilities while maintaining optimal tool performance and material quality.