Milling speeds and feeds depend on cutter geometry, flute count, aluminum alloy, engagement, machine capability, and setup rigidity. Haas publishes target cutting values for its HSAM2 metric end mills. The table below is limited to the manufacturer’s ISO 21–22 / VDI 21–22 wrought-aluminum slotting group and the listed three-flute cutter diameters. It is a tool-specific starting reference, not a universal setting for every aluminum cutter.

What this table covers

The source specifies a carbide HSAM2 end mill, a full slot width and axial depth of one tool diameter, and wrought aluminum alloy. It gives a common target cutting speed of 488 m/min across the listed diameters, while the feed per tooth, spindle speed, and feed rate vary with cutter size. Haas publishes these values as targets and advises starting with a middle or average value, then adjusting for the actual cutting conditions.

Do not use these rows for cast aluminum, high-silicon aluminum, copper alloys, plastics, a different cutter series, or side milling. Haas lists material groups separately. A different work material or cutting mode requires its own manufacturer data. The table also does not prove that the spindle, toolholder, workpiece, or machine can safely reach a listed RPM or feed rate.

How the parameters relate

Cutting speed is the peripheral speed at the cutter edge. Haas gives the relation Vc = π × D × n ÷ 1000 when diameter D is in millimetres and spindle speed n is in revolutions per minute. Feed rate is feed per tooth multiplied by spindle speed and the number of cutting edges: Vf = fz × n × Z. The three-flute assumption is built into the source values. If the flute count or tool diameter differs, recalculate from the appropriate toolmaker data rather than copying the listed feed.

A full slot engages the cutter across its diameter and to the stated axial depth, creating more load than a light radial engagement. A finishing pass, a narrow radial cut, or a long-reach cutter may require different conditions. Chip evacuation is especially important in aluminum: chips that pack into the flutes can damage the tool or workpiece. Use the coolant or air strategy specified for the cutter and machine, and keep hands clear of the cutting zone.

Adjust for the actual machine and tool

Compare the target spindle speed and feed with the machine’s real limits. If the control cannot reach a table RPM, Haas recommends adapting the feed in proportion to available RPM. Start conservatively, observe chip shape, sound, vibration, finish, and edge condition, and change one parameter at a time. Check that the tool is seated correctly, runout is acceptable, the workholding is secure, and the spindle is suitable for the required speed.

Haas advises reducing both feed and cut depth by 50% for long-flute or long-reach tools, reducing recommendations for harder-than-listed materials, and adjusting for less rigid conditions. These notes matter because the chart assumes ideal conditions. They are not a substitute for a tool-specific review of the exact cutter and setup.

When only part of the cutter width is engaged, the load and chip thickness differ from a full slot. Do not treat this slotting row as a direct side-milling setting; use a suitable side-cutting entry or a toolmaker method that accounts for radial engagement. Also distinguish programmed feed from the actual feed achieved when a control slows for corners or axis limits. Those changes can alter chip load even when the commanded feed appears unchanged.

Limits before production use

The rows do not guarantee tool life, dimensional accuracy, surface finish, power demand, or a safe operating envelope. Confirm alloy and temper, cutter number, flute count, stickout, holder, coolant, machine taper, workpiece support, and chip evacuation. For production, qualify the process on the actual machine and follow current Haas and cutter-manufacturer instructions.

Source: Haas Automation, HSAM2 End Mills Speeds and Feeds, Metric, slotting table for ISO N, VDI 21–22 wrought aluminum alloy. The document states that its values are targets, lists one-diameter slot width and depth, and includes machine and tool-length adjustment notes.