Holes in Aluminum

[jsmithconstruct]

A job requires cutting roughly 1200 holes in 5' x 10' aluminum sheets (1/4" thick). I plan on using an 1/8" dia single spiral-o bit in a spiral inside profile with ramp. .5 ips, .125 plunge rate at 14,000rpm.

I am getting an estimated time of 60 hours, does anyone have any suggestions on how to speed up this process?

[Rob Gunn]

What diameter of hole? I would just use a drill and Z axis feed into into the sheet.

[Brady Watson]

What diameter of hole? I would just use a drill and Z axis feed into into the sheet.

I would not do this if you have any love whatsoever for your router or spindle...Unless you are talking about mounting an actual drill motor and chuck onto the Z...

You want to do an inside profile cut using spiral ramp in PartWorks. The tool needs to be smaller than the hole to be cut. Slow those speeds down too because 1 inch per second on a 1/2" or smaller hole is way too fast.

-B

[jsmithconstruct]

Hole diameter is 1".

So Brady, the last thing I want to do is screw up my machine. Your recommendation would be not to take on this project?

[Brady Watson]

No - by all means, take on the project & make some cash!

If I were doing it, I would use a 1/4" single spiral-O with 5/16-3/8" length of cut max to reduce tool deflection. I'd run 13,000-15,000 RPM and step down .03-.05" per pass with a spiral ramp inside profile. I'd probably start at .7,.5 IPS speed and start to feather up the move speed towards 1 IPS on XY to see what I could get away with.

Run dust collection to aid in cooling the bit. No lubes or other coolant is required.

Remember one thing when cutting metals on the bot - NEVER plunge straight down!

Onsrud cutter should have the tool you need. Part number 63-774

-B

PS - Is it Creole tomato season yet?

[Brady Watson]

Onsrud lists the 63-774 as a 'soft plastic' tool - however I have cut a ton of AL with it. You also may be interested in a 65-023, which lists AL as an approved material.

I've dealt with these guys in the past & they are tip top on service: http://www.ballewsawandtool.com

-B

[knight_toolworks]

Myself if you are supplying the aluminum I would contact some waterjet places and get a quote. they get the material so cheap you could add some profit onto the quoter and do other work while they are cutting it.

[jsmithconstruct]

Thanks for all the helpful information!!