HSS End Mills for Aluminum

Engineered for high-speed aluminum machining. Available in Standard HSS or premium HSS-Co (M35/M42). Choose DLC coated or uncoated mirror-polished options to eliminate built-up edge and maximize chip evacuation.

HSS / HSS-Co (M35/M42) 3 Flutes DLC or Uncoated D6mm - D25mm Aluminum & Non-Ferrous Specialist
HSS End Mills for Aluminum
HSS End Mills for Aluminum

Procurement & Commercial Terms

MOQ1 pc (sample/stock) | 50 pcs (OEM/bulk)
Lead TimeSame day dispatch (standard stock) | 7–10 days (custom/OEM)
InventoryD6mm–D25mm full range in stock. Both standard and extra-long lengths available.
Material & CoatingSubstrate: HSS or HSS-Co (M35 / M42) | Coating: DLC or Uncoated (Mirror Polish)
PackagingIndividual plastic tubes + anti-rust paper | Rigid export cartons (50/100 pcs)
ShippingDHL/FedEx/UPS for samples | Air/Sea freight for bulk. Incoterms: EXW, FOB, CIF, DDP

HSS & HSS-Co 3-Flute Aluminum End Mill Specifications

Customizable Options: Material: Standard HSS or HSS-Co (M35/M42) | Coating: DLC or Uncoated | Tolerance: h6
ModelD (mm)H (mm)d (mm)L (mm)Stock
HSAL-3F-6-19-6-60619660● In Stock
HSAL-3F-8-25-8-66825866● In Stock
HSAL-3F-9-25-10-759251075● In Stock
HSAL-3F-10-25-10-7510251075● In Stock
HSAL-3F-11-35-12-8511351285● In Stock
HSAL-3F-12-35-12-8512351285● In Stock
HSAL-3F-13-35-12-8513351285● In Stock
HSAL-3F-14-35-12-8514351285● In Stock
HSAL-3F-15-42-16-9515421695● In Stock
HSAL-3F-16-42-16-9516421695● In Stock
HSAL-3F-17-42-16-9517421695● In Stock
HSAL-3F-18-42-16-9518421695● In Stock
HSAL-3F-19-50-20-110195020110● In Stock
HSAL-3F-20-50-20-110205020110● In Stock
HSAL-3F-21-50-20-110215020110● In Stock
HSAL-3F-22-50-20-110225020110● In Stock
HSAL-3F-23-60-20-125236020125● In Stock
HSAL-3F-24-60-20-125246020125● In Stock
HSAL-3F-25-60-20-125256020125● In Stock
ModelD (mm)H (mm)d (mm)L (mm)Stock
HSAL-3F-6-25-6-68625668● In Stock
HSAL-3F-8-38-8-83838883● In Stock
HSAL-3F-10-45-10-9510451095● In Stock
HSAL-3F-12-53-12-110125312110● In Stock
HSAL-3F-14-53-12-110145312110● In Stock
HSAL-3F-16-63-16-123166316123● In Stock
HSAL-3F-18-63-16-123186316123● In Stock
HSAL-3F-20-75-20-141207520141● In Stock
HSAL-3F-22-75-20-141227520141● In Stock
HSAL-3F-25-100-20-1602510020160● In Stock

● All sizes in stock | Diameter tolerance: h6 (0/-0.009mm for D≤10, 0/-0.011mm for D>10). Custom sizes available upon request.

Application Tip: The 3-flute geometry is critical for aluminum to maximize chip clearance and prevent built-up edge (BUE). For deep slotting where deflection is a concern, consider our Steel Series 4-flute tools, but ensure ample lubrication to prevent gummy aluminum from clogging the flutes.

HSS vs. HSS-Co (Cobalt) for Aluminum: Which to Choose?

Understanding the machining differences to optimize your tooling cost and performance in non-ferrous materials.

Feature Standard HSS HSS-Co (M35 / M42)
Cobalt Content0% (Trace)5% (M35) or 8% (M42)
Abrasion ResistanceGood (Standard Alloys)Superior (High-Silicon Alloys)
ToughnessHigh (Resists chipping)Slightly Lower
Ideal Workpiece MaterialsAluminum 6061, 5052, Pure Copper, Brass, PlasticsAluminum 7075, Cast Aluminum (high Si), Graphite, Continuous high-volume production
Cost Efficiency★★★★★ (Most Economical)★★★☆☆ (Higher Initial Cost, Longer Life in abrasive materials)
When to choose Standard HSS?

Choose standard HSS for general-purpose machining of soft aluminum alloys (like 6061 or 5052), brass, copper, and plastics. It offers the best upfront cost efficiency and excellent toughness for interrupted cuts or less rigid machine setups.

When to upgrade to HSS-Co?

Upgrade to HSS-Co (M35/M42) when machining abrasive materials like high-silicon aluminum (7075, cast aluminum) or graphite. The cobalt content drastically improves wear resistance against abrasive particles, preventing premature flank wear and extending tool life in continuous CNC production runs.

Why Choose Our 3-Flute Aluminum End Mills?

DLC Coating Option

Diamond-Like Carbon coating provides an ultra-low friction coefficient (<0.1), virtually eliminating built-up edge (BUE) and allowing for higher spindle speeds and smoother finishes.

Optimized 3-Flute Geometry

Larger gullet capacity compared to 4-flute tools ensures rapid, clog-free chip evacuation, which is critical for preventing re-cutting and edge damage in soft, gummy materials.

Mirror-Polished Edges

Our uncoated versions feature precision mirror-polished flutes. This ultra-smooth surface further reduces friction and prevents aluminum chips from welding to the cutting edge.

High Helix Angle

Designed with a higher helix angle (typically 45°) to shear aluminum efficiently, reducing cutting forces and enabling aggressive, high-feed machining strategies.

Material Compatibility Guide

Non-Ferrous Application Matrix
Workpiece MaterialRecommended SubstrateRecommended CoatingSuitabilityNotes
Aluminum (6061, 5052, 6063)HSS or HSS-CoDLC or Uncoated◎ ExcellentPrimary application. Use high RPM and air blast for optimal chip evacuation.
High-Silicon Aluminum (7075, Cast Al)HSS-Co (M35/M42)DLC◎ ExcellentHSS-Co is essential to resist the abrasive wear caused by silicon particles.
Copper / Brass / BronzeHSSUncoated or DLC◎ ExcellentUncoated mirror-polished tools excel here, preventing material smearing.
Plastics / Acrylic / WoodHSSUncoated◎ ExcellentSharp, uncoated edges provide the cleanest cuts without melting the material.
Carbon Steel / Alloy Steel--✗ Not RecommendedThese tools lack the heat resistance and core strength for ferrous materials. Use our 4-flute steel series.

◎ = Excellent | ✗ = Not Recommended

Typical Applications for 3-Flute Aluminum End Mills

Aerospace & Automotive Parts

High-speed pocketing and profiling of 7075 aluminum structural components, heat sinks, and engine blocks where chip evacuation is critical.

CNC Enclosures & Electronics

Machining of aluminum chassis, heatsinks, and electronic enclosures. DLC coating ensures a bright, burr-free surface finish without material adhesion.

General Aluminum Fabrication

Versatile tool for job shops handling mixed batches of 6061 aluminum, brass, and copper. The 3-flute design offers a perfect balance of speed and finish.

CAM Setup & Cutting Parameters Guidance

Recommended Cutting Data (HSS-Co + DLC)
Workpiece MaterialCutting Speed (Vc)Feed per Tooth (fz)Coolant Recommendation
Aluminum (6061, 5052)300 - 600 m/min0.05 - 0.15 mm/toothAir Blast or MQL (Flood acceptable)
High-Silicon Aluminum (7075)200 - 400 m/min0.04 - 0.10 mm/toothAir Blast or MQL
Copper / Brass150 - 300 m/min0.04 - 0.12 mm/toothAir Blast or Flood Coolant
Plastics / Acrylic200 - 400 m/min0.05 - 0.15 mm/toothAir Blast (to prevent melting)

*For standard uncoated HSS, reduce Cutting Speed (Vc) by approximately 15-20% to maintain edge integrity.

Best Practices for Aluminum Milling
  • ⚠️ Always Use Climb Milling - Conventional milling pushes chips back into the cut, causing re-cutting and built-up edge in aluminum.
  • ⚠️ Maximize Chip Evacuation - Use high-pressure air blast to clear chips from the gullets. Clogged flutes are the #1 cause of tool failure in aluminum.
  • ⚠️ Avoid Dwell Marks - Maintain a constant feed rate. Pausing the tool in the cut will cause the aluminum to weld to the cutting edge.
  • ⚠️ Rigidity is Key - Keep tool overhang to an absolute minimum. Use the shortest possible length of cut (H) for your application to prevent chatter.
  • ⚠️ DLC Care - While DLC is incredibly hard, it can be brittle. Avoid heavy interrupted cuts or dropping the tool into the material.
  • ⚠️ Sharpness Matters - Uncoated tools must be kept razor-sharp. A dull tool will rub and generate heat, melting plastics or gumming up aluminum.

Factory Production & Quality Control

HSS aluminum end mill grinding and polishing

Manufacturing Process & QA Steps

  • 🔹 Raw Material: Premium HSS and HSS-Co (M35/M42) steel blanks sourced from certified mills.
  • 🔹 Grinding: 5-axis CNC tool grinders create the precise 3-flute geometry and high helix angle for optimal chip flow.
  • 🔹 Polishing: Uncoated versions undergo a specialized mirror-polishing process on the flutes to minimize friction.
  • 🔹 Coating: DLC coating applied via advanced PVD process, ensuring uniform thickness and strong adhesion without altering the sharp edge.
  • 🔹 Inspection: 100% visual inspection under microscope. Batch sampling for coating thickness, hardness, and real-world aluminum cutting tests.

Frequently Asked Questions

A 3-flute design provides larger chip clearance (gullet) compared to 4-flute tools, which is essential for preventing clogging and built-up edge (BUE) when machining soft, gummy materials like aluminum.

DLC (Diamond-Like Carbon) coating provides an ultra-low friction surface that drastically reduces the tendency of aluminum to weld to the cutting edge. It is highly recommended for high-speed machining to improve surface finish and extend tool life.

No, these tools are specifically optimized for non-ferrous materials. The geometry is designed for chip evacuation in soft materials, not for the rigidity and heat resistance required for steel. Please use our dedicated Steel Series for ferrous metals.

Yes. While standard HSS is sufficient for most aluminum applications, our HSS-Co (M35/M42) versions are recommended for machining high-silicon aluminum alloys (like cast aluminum) or for long continuous production runs where extended tool life is required due to the abrasive nature of silicon.

Request Quote for HSS End Mills for Aluminum

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