Cutting Aluminum

[GlenP]

Hey everyone. I have had several requests in the past to cut aluminum on my PRS standard and have always turned it down. Now I have a customer that I cut wood and acrylics for needing me to take on their aluminum parts. I have a fellow botter that has done metal with the proper bit and cooling fluid misting on the bit. If I did it this way I would need a tray to catch coolant and not make mess of cnc bed. Anybody cut 1/4" or 1/2" aluminum?
Hope your all busy.

Glen

[dlcw]

Glenn, cutting aluminum has been touched on several times on this forum. If you do a search I think you will find lots and lots of really good info.

[dana_swift]

Glen- when I cut Al, I just put compressed air directly on the bit. It blows away the chips and helps cool the bit. No fluids at all.

Keep the cuts very shallow and much smaller chiploads.

Its worked for me, I have cut Al, Copper, Brass, etc..

D

[GlenP]

Thanks Dana. What type of bit did you use? I have seen some solid carbide ones on different sites.
I am going to get some aluminum from the customers as they will be supplying their own. The company I am going to be doing this for is one of the largest Canadian suppliers to municipalities so there will be lots of cutting. I have been looking into plasma cnc machines but I would like to have the bot do it if it can.
Love to have a dedicated machine for metal but shop and budget doesn't allow it.....yet

[dana_swift]

Here is a snippet of a video of how I have done it:

http://www.youtube.com/watch?v=CzigLEGIFkM

That was an early effort (very successful). Since then I have used pretty much the same method, with better air blowing on the bit.

In this case I used a 1/8" end mill. I have also used 1/4.

D

[dhunt]

Here is a snippet of a video of how I have done it:

http://www.youtube.com/watch?v=CzigLEGIFkM

Interesting!

Didn't someone in here speak about misting with alcohol while cutting?
Alcohol cools like crazy ..while evaporating away
.

[araugh]

Here is a snippet of a video of how I have done it:

http://www.youtube.com/watch?v=CzigLEGIFkM

That was an early effort (very successful). Since then I have used pretty much the same method, with better air blowing on the bit.

In this case I used a 1/8" end mill. I have also used 1/4.

D

What bit are you using here? Thanks!

[GlenP]

I just order couple Onsrud bits # 63-622 which are a o flute end mill. They recommend misting or fluid to make last longer but I am going to try Dana's suggestion of air and see how it goes. Thanks for the help. If this works for me it will open some new doors and opportunities.

[kg4mon]

I cut aluminum all the time with by bot. I use a onsrud o flute 1/4. I move at 1.25-1.5 ips and .015-.020 deep per pass. No fluid at all. Just air.

[donek]

I cut aluminum all the time with by bot. I use a onsrud o flute 1/4. I move at 1.25-1.5 ips and .015-.020 deep per pass. No fluid at all. Just air.

Just ran 250 1in X 2in X1/2 parts over the weekend with this bit:
http://www1.mscdirect.com/cgi/NNSRIT...-SearchResults
no air or coolant and the bit is still working fine. I actually sharpen these bits all the time on my grinder. A single flute bit is very easy to regrind the bottom surface/cut down. Machine time was 24mins per 8 parts, so a total of 12.5hrs. I use a PC router at 1800rpm. Typical feed speed is 1.2in per second on finish cuts and 2in per second on roughing cuts. Pass depth of 0.050in. If you don't need/want sharp corners at the bottom of your profiles, slightly rounding over the point of the cutter will produce a better surfacing finish.