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Switched from a 3-flute to a 5-flute end mill for finishing aluminum, and the surface went from a 32 to a 16 finish in one pass.
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black.val2mo ago
Honestly, that's a huge improvement. @phoenixpalmer is right about the finer cut. Tbh, it reminds me of when we had to finish some tight pockets in 6061 and just changing the helix angle on our end mill made the chips clear way better, no more built-up edge. Sometimes the small tweaks are what get you there.
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That's a solid jump in finish quality. More flutes usually means a finer cut in aluminum because each tooth takes a smaller bite. You get less chatter and a smoother surface. It's a simple switch that makes a huge difference on the final part. Good proof that tool geometry matters just as much as speed and feed.
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