AEX Series End mill for aluminum
Ball Nose End Mill for Aluminum Machining | AEX Series
Range reference: KVX-010
- workpiece material
- Aluminum; Copper alloy; Magnesium alloy; Aluminium-silicon alloy
- application type
- Roughing
- flute type
- Ball Nose End Mill
- Coating
- No Coating or DLC
• 0.8 μm carbide with 10% cobalt • Uncoated or DLC coating for aluminum machining • 45° helix angle for smooth chip evacuation • Positive rake angle for lower cutting resistance • Designed for 3D contouring and surface finishing of aluminum
Enquire about this tool →Technical data
| Specification | R | Flute length(H) | Shank diameter(d) | Overall Length(L) |
| 2F R0.50X2XD4X50-AEX | 0.5 | 2 | 4 | 50 |
| 2F R0.75X3XD4X50-AEX | 0.8 | 3 | 4 | 50 |
| 2F R1.0X4XD3X50-500 | 1.0 | 4 | 3 | 50 |
| 2F R1.0X4XD4X50-AEX | 1.0 | 4 | 4 | 50 |
| 2F R1.25X5XD4X50-500 | 1.3 | 5 | 4 | 50 |
| 2F R1.25X6XD4X50-AEX | 1.3 | 6 | 4 | 50 |
| 2F R1.5X6XD3X50-500 | 1.5 | 6 | 3 | 50 |
| 2F R1.5X6XD4X50-AEX | 1.5 | 6 | 4 | 50 |
| 2F R1.5X6XD6X50-500 | 1.5 | 6 | 6 | 50 |
| 2F R1.75X7XD4X50-500 | 1.8 | 7 | 4 | 50 |
| 2F R2.0X8XD4X50-AEX | 2.0 | 8 | 4 | 50 |
| 2F R2.0X8XD6X50-AEX | 2.0 | 8 | 6 | 50 |
| 2F R2.5X10XD5X50-500 | 2.5 | 10 | 5 | 50 |
| 2F R2.5X10XD6X50-AEX | 2.5 | 10 | 6 | 50 |
| 2F R3.0X12XD6X50-AEX | 3.0 | 12 | 6 | 50 |
| 2F R4.0X16XD8X60-AEX | 4.0 | 16 | 8 | 60 |
| 2F R5.0X20XD10X75-AEX | 5.0 | 20 | 10 | 75 |
| 2F R6.0X25XD12X75-AEX | 6.0 | 25.0 | 12.0 | 75 |
| 2F R7.0X30X14X100-500 | 7.0 | 30.0 | 14.0 | 100 |
| 2F R8.0X30XD16X100-500 | 8.0 | 30.0 | 16.0 | 100 |
| 2F R8.5X50X18X100-500 | 8.5 | 50.0 | 18.0 | 100 |
| 2F R9.0X30X18X100-500 | 9.0 | 30.0 | 18.0 | 100 |
| 2F R9.5X50X20X100-500 | 9.5 | 50.0 | 20.0 | 100 |
Additional technical data
| Suitable Materials | Typical Applications |
|---|---|
| 6000 series aluminum alloys | 3D contour milling |
| 6061 aluminum | Curved surface finishing |
| 7000 series aluminum alloys | Profile milling |
| 7075 aluminum | Mold cavity machining |
| Aluminum-silicon alloys | Multi-axis aluminum machining |
| Magnesium alloys | Semi-finishing and finishing |
| Copper alloys | Surface finishing of aluminum parts |
| Engineering plastics | Prototype and precision component machining |
Additional technical data
| Item | AEX Flat End Mill | AEX Ball Nose End Mill |
| Tool Type | Flat end mill | Ball nose end mill |
| Cutting Shape | Flat bottom cutting | Spherical cutting |
| Contact Area | Full edge contact | Point & arc contact |
| Main Purpose | Slotting, side miling, facing | 3D contouring, profiling,surface finishing |
| Surface Result | Flat surfaces,sharp corners | Smooth curved surfaces |
| Typical Machining | Slots,shoulders,pockets | Mold cavities, complex shapes,3D surfaces |
| Cutting Efficiency | High material removal rate | Stable cutting in continuous contours |
| Recommended Operation | Roughing & semi-finishing | Finishing &semi-finishing |
Technical notes
- The AEX ball nose end mill for aluminum machining is designed for high-speed 3D contouring, curved surface finishing, profile milling, and mold cavity machining of aluminum and other non-ferrous materials.
- Made from imported fine-grain carbide with 0.8 μm grain size and 10% cobalt content , this aluminum ball nose end mill provides stable edge strength, sharp cutting performance, and reliable wear resistance for continuous aluminum machining.
- The tool adopts a sharp positive rake geometry, precision-ground cutting edge, 55% small-core design, and 45° helix angle . This helps reduce cutting resistance, improve chip evacuation, and achieve smoother surface finish in aluminum machining.
- AEX is KERNVEX' s dedicated aluminum end mill series. For aluminum parts that require smooth curves, complex 3D profiles, and clean surface transitions, the AEX ball nose end mill provides a stable and practical solution.
- Fine-Grain Carbide Material The AEX ball nose end mill is produced from imported carbide rods with 0.8 μm grain size and 10% cobalt content . This carbide substrate provides a good balance of hardness, toughness, and wear resistance for aluminum and non-ferrous material machining.
- Uncoated or DLC Rainbow Coating The tool is available in uncoated and DLC Rainbow coated versions. The uncoated version provides a sharp cutting edge for smooth aluminum cutting, while the DLC Rainbow coated version helps reduce friction, improve anti-adhesion performance, and lower the risk of built-up edge. Aluminum adhesion is a common machining issue, and this topic is explained in more detail in our guide: Why Does Aluminum Stick to an End Mill?
- Positive Rake Geometry The tool adopts a 6° end rake angle and 12° side rake angle . This sharp cutting geometry helps reduce cutting resistance, improve cutting smoothness, and minimize burr formation during aluminum machining.
- Precision-Ground Cutting Edge The cutting edge is precision-ground with a 1200-grit grinding wheel to maintain edge sharpness. This helps reduce burrs, avoid uneven surface marks, and improve the final surface quality of aluminum parts.
- 55% Core Diameter and 45° Helix Angle The tool uses a 55% small-core diameter and 45° helix angle . The smaller core provides larger chip space, while the high helix angle supports smoother chip evacuation and lower cutting resistance during high-speed aluminum cutting.
- AEX ball nose end mills are suitable for aluminum and non-ferrous materials, including:
- For 6061 aluminum machining, tool sharpness and chip evacuation are especially important. More selection details can be found in Best End Mill for 6061 Aluminum
- For harder aluminum alloys such as 7075, coating selection, rigidity, and cutting parameters become more important. Related guide: Best End Mill for 7075 Aluminum
- Typical applications include:
- • 3D contour milling
- • Curved surface finishing
- • Profile milling
- • Mold cavity machining
- • Surface finishing of aluminum parts
- • Multi-axis aluminum machining
- • Semi-finishing and finishing of complex aluminum components
- • Prototype aluminum part machining
- • Aerospace, automotive, electronics, and mold applications
- Different aluminum machining tasks require different tool geometries. AEX flat end mills and AEX ball nose end mills are designed for different cutting purposes.
- For flat surfaces, slots, pockets, and straight side walls, an AEX flat or square end mill is usually more efficient.
- For curved surfaces, 3D profiles, mold cavities, and complex aluminum contours, an AEX ball nose end mill provides smoother surface transitions and better finishing performance.
- The difference between these two tool shapes is also explained in our aluminum machining guide: Square End Mill vs Ball Nose End Mill for Aluminum
Technical illustrations and dimension data
