Cutting Size Aluminum Rod 2024 2014 2017 5052 5056 5083 6061 6063 6082 7075 Aluminio Round Bar

Alloy Series & Characteristics

1. 2xxx Series (2014, 2024, 2017)

   • Properties: High strength (copper-based), heat-treatable, lower corrosion resistance.

   • Cutting Tips:

     • Use carbide-tipped tools to handle hardness and reduce wear.

     • Moderate cutting speeds to avoid overheating; lubrication (e.g., cutting oil) recommended.

     • Watch for chip buildup—clear frequently to prevent tool clogging.

2. 5xxx Series (5052, 5056, 5083)

   • Properties: Magnesium-based, excellent corrosion resistance (especially 5083), prone to work hardening.

   • Cutting Tips:

     • Sharp, high-speed steel (HSS) or carbide tools to prevent galling.

     • Higher feed rates to avoid work hardening; minimize dwell time.

     • Coolant helps manage heat and reduce hardening.

3. 6xxx Series (6061, 6063, 6082)

   • Properties: Magnesium-silicon, excellent machinability, widely used in structural applications.

   • Cutting Tips:

     • Standard HSS tools work well; moderate speeds and feeds.

     • Minimal lubrication required for smoother cuts.

     • Ideal for band saws or circular saws with fine-toothed blades.

4. 7xxx Series (7075)

   • Properties: Zinc-based, ultra-high strength (aerospace use), challenging to machine.

   • Cutting Tips:

     • Carbide tools mandatory due to hardness.

     • Slow cutting speeds with ample coolant to dissipate heat.

     • Avoid excessive force to prevent tool breakage.

Cutting Methods & Tools

• Band Saw:

  • Use a bi-metal blade (10–14 teeth per inch for large diameters; finer teeth for thin rods).

  • Coolant recommended for harder alloys (e.g., 2024, 7075).

• Circular Saw/Chop Saw:

  • Carbide-tipped blades with negative rake angles reduce grabbing.

  • Secure the rod firmly to minimize vibration.

• Shearing:

  • Suitable for softer alloys (5052, 6061) and small diameters (<1").

  • Avoid for harder alloys (risk of deformation or tool damage).

• Lathe/Machining:

  • Ideal for precision cuts; use sharp inserts and coolant.

  • Higher spindle speeds for 6xxx series; slower for 2xxx/7xxx.

Key Considerations

• Work Hardening: Critical for 5xxx alloys—maintain consistent feed rates.

• Heat Management: Overheating can soften 6xxx alloys or harden 5xxx/7xxx. Use coolant/lubricant.

• Deburring: File or sand edges post-cut; aluminum chips are sharp.

• Safety: Wear PPE (gloves, goggles, respirator for dust).

Rod Size & Tool Selection

• Small Diameters (<1/2"): Hacksaw, shear, or abrasive cutter.

• Medium Diameters (1/2"–4"): Band saw or circular saw.

• Large Diameters (>4"): Heavy-duty band saw with coolant feed.