535 Cast Aluminum Speeds and Feeds (Milling, Drilling, Turning)

    Carbide end mills in 535 Cast Aluminum: 400–950 SFM. Also called Almag 35. Chart row used: “Aluminum Cast” (As cast).

    Starting point: carbide end mills

    RPM and IPM use the low end of the published range (400 SFM and the lowest chip load for each diameter range). RPM = SFM × 12 ÷ (π × D); IPM = RPM × flutes × chip load.

    535 Cast Aluminum — inch end mills
    DiameterChip load (in/tooth)RPMIPM · 2 fluteIPM · 3 flute
    1/8".000612,22314.722.0
    1/4".00086,1129.814.7
    3/8".00154,07412.218.3
    1/2".00253,05615.322.9
    3/4".00352,03714.321.4
    1".00501,52815.322.9
    535 Cast Aluminum — metric end mills (inch chip-load range the size falls in)
    DiameterChip load (in/tooth)RPMIPM · 2 fluteIPM · 3 flute
    3 mm.000612,93615.523.3
    6 mm.00086,46810.315.5
    10 mm.00253,88119.429.1
    12 mm.00253,23416.224.3
    16 mm.00352,42617.025.5
    20 mm.00501,94019.429.1
    Full published chip-load ranges
    • 1/32-1/8": .0006–.0015"
    • 1/8-1/4": .0008–.0018"
    • 1/4-3/8": .0015–.0040"
    • 3/8-1/2": .0025–.0045"
    • 1/2-3/4": .0035–.0080"
    • 3/4-1": .0050–.0100"

    Calculator — prefilled for 535 Cast Aluminum

    Results for Milling

    Spindle RPM
    3,056
    Feed
    30.6 IPM
    Chip load
    0.0023 in
    MRR
    1.15 in³/min
    Power
    — HP
    Torque
    — lbf·ft
    Programmed fz
    0.0025 in
    Actual SFM
    400
    Spindle use
    25%
    • Pick a material in the library below to estimate spindle power and torque.

    Material library

    Tool & coating guidance

    Grade, edge geometry and coating determine usable cutting data. Sharp polished edges can suit nonferrous work; substrate and geometry still govern. Coated vs uncoated carbide changes turning data only; no coating speed multiplier is inferred.

    Tool & cut parameters

    Manual values
    Chip thinning & cutter body
    %
    Radial factor ×1.09Angle factor ×1.00Programmed fz 0.0025 inMax chip hex 0.0023 in

    Fixed-angle peripheral estimate: hex = fz × radial factor × sin(KAPR). No radial correction at ≥50% engagement. Not a centered face-milling or ball-nose model. Sandvik geometry reference

    Insert styles, guidelines & formulas

    RPM = (SFM × 12) / (π × D) | Feed = RPM × programmed fz × effective zc | MRR = WOC × DOC × feed | HP = Kp × C × MRR × 1.1 ÷ 0.8 (Machinery's Handbook)

    Square (SEMT/SNMG)
    General purpose, 90° lead angle
    Round (RPMW/RCKT)
    Ramping, 3D contouring, high feed
    Triangular (TPMX)
    Light cuts, finishing
    Octagonal (ONMU)
    Face milling; HFM suitability is body-specific

    Milling Guidelines

    • Start at 70% of max SFM, increase gradually
    • Chip load too low → rubbing & heat buildup
    • Use climb milling when machine rigidity allows
    • Radial engagement >50% → reduce feed per tooth
    • Round inserts: best for ramp-in and 3D surfaces
    Open in the full calculator workspace

    Speeds by tool material

    Published starting ranges for 535 Cast Aluminum by operation and tool material. Rows marked * are estimates.

    535 Cast Aluminum — speeds by tool material
    OperationToolSFMFeedSource row
    millingHSS *1650.0025–0.0045 in/toothLittleMachineShop · Cast aluminum (Sand and permanent mold casting alloys)
    millingCobalt HSS (M35/M42) *1650.0025–0.0045 in/toothLittleMachineShop · Cast aluminum (Sand and permanent mold casting alloys)
    millingSolid carbide end mill400–9500.0025–0.0045 in/toothLakeshore Carbide · Aluminum Cast
    millingUncoated carbide (H10)2650–30500.0040–0.0080 in hexSandvik milling (large engagement) · CMC 30.21 Cast aluminum, not aged
    millingCoated carbide (GC1030)2750–32500.0040–0.0080 in hexSandvik milling (large engagement) · CMC 30.21 Cast aluminum, not aged
    millingCermet (CT530)2900–34000.0040–0.0080 in hexSandvik milling (large engagement) · CMC 30.21 Cast aluminum, not aged
    millingPCD (CD10)5250–61500.0040–0.0080 in hexSandvik milling (large engagement) · CMC 30.21 Cast aluminum, not aged
    turningHSS600–7500.0040 in/revLittleMachineShop · Cast aluminum (Sand and permanent mold casting alloys)
    turningCobalt HSS (M35/M42) *600–7500.0040 in/revLittleMachineShop · Cast aluminum (Sand and permanent mold casting alloys)
    turningUncoated carbide (H10)820–65500.0060–0.0310 in/revSandvik turning · CMC 30.21 Cast aluminum, not aged
    turningPCD (CD10)820–65500.0020–0.0160 in/revSandvik turning · CMC 30.21 Cast aluminum, not aged
    drillingHSS350–400—LittleMachineShop · Cast aluminum (Sand and permanent mold casting alloys)
    drillingCobalt HSS (M35/M42) *350–400—LittleMachineShop · Cast aluminum (Sand and permanent mold casting alloys)

    Machinist tips

    Chip thinning
    At light radial engagement (under half the cutter diameter) the real chip is thinner than the feed per tooth. Raise the feed to keep the chip at the chart value, or the tool rubs and wears.
    Climb vs conventional
    On a rigid CNC, climb mill so each tooth starts thick and exits thin. Use conventional milling on machines with backlash or on hard scale skins.
    Coolant and chip evacuation
    Flood coolant or a strong air blast keeps chips from welding to the flutes. Use 2 or 3 flutes for room to clear chips.

    Common questions

    What SFM should I use for 535 Cast Aluminum?
    Lakeshore Carbide – General Purpose End Mill Speeds & Feeds lists 400–950 SFM for carbide end mills in the "Aluminum Cast" row. Start at the low end and adjust for your machine.
    What chip load for a 1/2" end mill in 535 Cast Aluminum?
    The published range for 3/8–1/2" carbide end mills is .0025–.0045" per tooth. At 400 SFM a 3-flute 1/2" end mill runs about 3056 RPM and 22.9 IPM.
    Are these values for HSS tools, drilling or turning?
    The end mill chart covers carbide end mills. The "Speeds by tool material" table adds published HSS, turning-insert and drilling rows for 535 Cast Aluminum where a source lists them (LittleMachineShop, Sandvik Coromant).
    390 Hypereutectic Cast Aluminum speeds and feeds4032 Aluminum speeds and feeds6061 Aluminum speeds and feeds

    Sources

    Starting values only. Adjust for rigidity, tool manufacturer data and machine.

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