Material Selection Based on Manufacturing Process

Machining Process

Aluminum
Pure Aluminum produces continuous chip which may clog the tools. Excellent tool life obtained with HSS tools

Copper Alloys
Pure copper produces thick chips, requires high forces at low cutting speed. Alloying improves the machinability.
Cu-Zn alloy, 60/40 brass possess good machinability.

Carbon Steels
Low-carbon steels are ductile and do not machine well.
Free-cutting steels give longer life, better surface finish, reduced tool forces

Alloy Steels
Some alloying elements improve machinability by reducing ductility of iron. Free cutting stainless steel containing sulphur or selenium has better machinability.
Nickel alloys
Difficult to machine
Cast Iron
Very poor machining

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