HPAS | Aluminium Specialized End Mills

The HPAS line of Aluminium Specialized End Mills is meticulously engineered to meet the demanding requirements of modern aluminium machining. Developed by Palbit with a deep understanding of the challenges associated with cutting aluminium alloys, this range is purpose-built to deliver outstanding performance, productivity, and surface quality across a variety of operations.

Aluminium machining presents unique obstacles, such as material adhesion, long chip formation, and thermal distortion – all of which demand cutting tools with specific geometries, coatings, and flute designs. The HPAS line addresses these needs through advanced engineering, offering solutions that ensure optimal chip evacuation, high material removal rates, and excellent dimensional accuracy.

With tailored designs for different machining strategies – from roughing to finishing, flat surface cutting to 3D profiling – the HPAS portfolio covers a wide range of applications in industries such as aerospace, automotive, mould & die, and general engineering.

Its diverse geometries empower machinists to overcome process limitations while achieving the high precision, efficiency, and consistency expected in today’s competitive manufacturing landscape.

HR35HPAS | Corner Radius End Mill

This corner radius end mill provides enhanced tool strength and reduced chipping, making it ideal for roughing and finishing aluminium aerospace components.

■ 3 Flutes
■ Unequal pitch to minimize vibrations
■ Robust cutting edge for high material removal rates

HF45HPAS | Flat Top End Mill

Featuring a flat cutting profile, this end mill is optimized for high material removal rates and excellent flatness in aluminium machining. It’s ideal for roughing, pocket milling, and precision flat surface machining in automotive and general engineering applications.

■ 3 flutes
■ Precision-ground cylindrical edge to minimize chatter and vibration
■ Polished w flute shape for efficient chip evacuation

HB50HPAS | Ball Nose End Mill

This long-reach ball nose end mill is engineered for demanding applications, combining durability and high material removal rates with an improved finish. Its geometry makes it ideal for 3D contouring and finishing, producing smooth cuts and high-quality surface finishes on curved surfaces, molds, dies, and complex components such as those found in aerospace turbines.

■ 2 Flutes
■ Reduced neck strengthens deep and long-reach cuts
■ High helix geometry enables high-performance shearing

Aluminium Specialized End Mills

PHT Coating

The new PHT coating, a TiB₂-based solution, is specifically engineered for high-performance machining of non-ferrous materials such as aluminium, where conventional coatings often fail due to material adhesion and built-up edge (BUE) formation.Thanks to its unique chemical composition, PHT exhibits virtually no affinity to aluminium and other soft metals, effectively eliminating material sticking and reducing tool wear.

The coating’s nanocrystalline, ultra-dense, and exceptionally smooth PVD-deposited structure ensures optimized adhesion to the substrate, combining superior hardness with excellent thermal stability. This powerful combination not only extends tool life but also enables higher cutting speeds and feeds, resulting in improved process reliability, reduced downtime, and maximum productivity.

Moreover, PHT’s resistance to oxidation and wear makes it ideal for applications involving elevated temperatures and challenging machining conditions, guaranteeing consistent, high-quality surface finishes and cost-efficient manufacturing.

PHT910 FEATURES

■ Low affinity to non-ferrous materials, especially aluminium
■ Excellent protection against built-up edges
■ Provides maximum lubricity and tool life
■ Top performance on aluminium applications

Main features of HPAS line:

■ Optimized geometry design delivering exceptional performance and setting industry benchmarks in aluminium machining
■ Polished flutes ensure efficient chip evacuation with minimal friction
■ PHT coating prevents adhesion due to its low affinity for aluminium
■ Long tool life with excellent surface finish and low energy consumption

Where innovation meets aluminium machining excellence

Challenges of Machining Aluminium

Nowadays, aluminium alloys dominate many industries, from aerospace to automotive, thanks to their workable properties, such as being lightweight and corrosion-resistant, as well as having excellent thermal and electrical conductivity.

Machining aluminium alloys is generally easier than machining metals such as steel or stainless steel, thanks to aluminium’s lower density and excellent machinability. However, several challenges can arise that require attention to ensure a productive solution.

Here are some common difficulties in machining aluminium alloys:

■ Built-up edge (BUE):

Aluminium tends to stick to the cutting tool, resulting in material building up on the tool edge. This has a negative effect on tool life, cutting performance, and surface finish.

■ Chip control:

Aluminium produces long, stringy chips that can wrap around the tool or interfere with the machining process.

■ Thermal expansion:

Aluminium has a high coefficient of thermal expansion, which can cause part distortion during machining and affect dimensional accuracy.

■ Tool wear:

Some high-strength aluminium alloys contain abrasive elements that cause rapid tool wear.

Overcoming these challenges requires selecting the right tools and optimising cutting conditions. With proper planning and refined machining techniques, productivity can be increased, tool life extended and surface quality improved.

Palbit’s new HPAS end mill line is the ideal solution to these challenges.