Luminum: Rod & Bar Machining Guide

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
Alloy	Diameter (Inches)	Multi Spindle	Single Spindle	Feed In/Rev
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		450	.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		450	.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
Alloy	Stock Diameter (Inches)	Multi Spindle	Single Spindle	Feed In/Rev
2011-T3	1/4	700 - 1100	700 - 1100	.0125
	3/8	700 - 1100		.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
Alloy	Stock Diameter (Inches)	Multi Spindle	Single Spindle	Feed In/Rev
2011-T3	1/4	700 - 1100	700 - 1100	.0025
	3/8	700 - 1100		.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
Alloy	Width of Cut (Inches)	Multi Spindle	Single Spindle	Feed In/Rev
2011-T3	3/8	700 - 800	700 - 1100	.0050
	1/2	700 - 800		.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
Alloy	Tool	Multi Spindle	Single Spindle	Spindle Rev
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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