Workpiece
Other materials are coming — tables need verification before they go live. Today everything assumes 6061 aluminum.
Tool
Common: 0.0625, 0.125, 0.25, 0.375, 0.5, 0.75
Pocket / Adaptive: 2–3 flutes preferred for chip evac; 4 OK for shallow. Facing & Contour: 4–8 flutes give better finish.
Caps the maximum axial DOC the tool can reach.
Setup & Machine
Not sure? Pick 2 or 3 to scale things back.
Be sure to tram the vise and shortest tool stickout without crashing the spindle. Double/Triple check!
Hard ceiling — recommendations never exceed this.
Auto-suggested. Tools ≥ 1/8" cap at 6000; under 1/16" or engraving allow up to machine max.
Operation
Pocket / Adaptive: heavy chip removal. Facing: skim the top flat. Contour: finish the wall around a part. Drilling: peck cycle (G73 chip-break + G83 full-retract).
Conservative: lower SFM, modest DOC, lots of margin. Best for new setups, unfamiliar tools, listening to your machine.
Pro mode: assumes a rigid machine, sharp tool, known work-holding, and chip evacuation. Verify on a test cut.
Recommended starting point
Spindle
—RPM
Cut feed
—IPM
Plunge feed
—IPM
Axial DOC
(max stepdown)
(max stepdown)
—in
Radial DOC
(optimal load)
(optimal load)
—in
SFM
(surface speed)
(surface speed)
—ft/min
Chip load
(per tooth)
(per tooth)
—in
Listen to the spindle. Smooth hum, no chatter or squeal = good. If the setup feels off, recompute conservatively.
For Aluminum: bright silver chips curling away = good; chips welding to the flutes or packing in a pocket = stop, more lube/coolant or back the feed off.
For Steel: blue chips curling away = good; brown/black chips = stop, you're burning the tool.
For Aluminum: bright silver chips curling away = good; chips welding to the flutes or packing in a pocket = stop, more lube/coolant or back the feed off.
For Steel: blue chips curling away = good; brown/black chips = stop, you're burning the tool.