Cutting Aluminum

[mmccue29]

I need to cut some aluminum, what feed rates and rpm's should I try with a 1/4 and 1/8 inch bits?

[aaasigncom]

USE THE SEARCH FEATURE
THERE IS ALOT OF INFO ON THIS BOARD ABOUT ALUMINUM

[jeffreymcgrew]

also talk to whomever you buy your bits from. Several vendors have special bits for this, and it makes a difference. They can tell you good speeds to use with their special bits. We've used the Onsrud and Amana aluminum bits in the past, they have a sharper upcut angle to them and special flutes. It made a big difference in how well it worked...

[mmccue29]

Thanks

I tried to do a search but did not have any luck.

I will call Onsrud.

Thanks again

[Brady Watson]

Search this board using "Cutting Aluminum" via Google (http://tinyurl.com/29vm8x)

-B

[mmccue29]

Brady,
That search worked great. Thanks I was trying to search using the form.

[gwilson]

I have not had a call to cut aluminum yet. But bookmarked that search for future use. Great info.

[mmccue29]

Brady,

I cut the aluminum today. The information I used was from a old post you did. It turned out great. Right on the money with rpm's and feed rates. I did get bits from onsrud.

Thanks for all your help.

[tuck]

I always give it an occasional spray with WD-40 to keep everything lubed when cutting thicker (.080) aluminum, but hey, that's just me. :-)

[Brady Watson]

Mike,
Glad it worked out for you! Most of the problems that people encounter when cutting AL on the Bot boils down to one of 2 things:

1) Inadequate hold-down method that causes vibration & tool breakage.

2) Incorrect chipload and cooling method, typically too light of a chipload causing melting of the material to the bit & bit breakage due to overheating (and AL build-up on the bit)

-B

[mmccue29]

The customer picked up the Aluminum today. He was thrilled.

I did spray with WD, that worked great.

Thanks for everyones help.

[aaasigncom]

using the info on this forum, i set my system up to cut aluminum. i added and air and separate kool mist nozzle to my home made dust shoe. i cut several sheets of .080 aluminum. the results were impressive. with air & lubrication, the aluminum cut like butter with no chatter marks. 1/4" 2 flute onsrud cutter - climb milling 30ipm. 16000rpm. coolant 75% alcohol 25% water. with a few drops of dish soap. the slight foam seams helps cooliing. the compressed air was at 30#. the aluminum was 45 degrees. using a laser thermometer the cutter tip was only 61 degrees from the first sheet to the last. i use a 1/4" spoil board of whatever is on hand. with .080 material i cut .16 to move the cutting edge away from the cutter tip for better heat disipation. using 75% alcohol, the spoilboard is dry before the machine gets to the other end of the table.

with the wealth of info on this forum, there is no reason to be gun shy about doing something new, if you do you home work. and make listen to everything brady watson says

my 2 cents worth -- www.AAASIGN.com (http://www.AAASIGN.com) INDY

[wcsg]

My alum cutting is a little different. I use Belin single flute spiral bits.

My usual alum thickness's are usually .040-.125. This thickness for the likes of a Belin bit is a cake walk

For 1/4" CED I can step at .125". 12,200 RPM's @ 1"IPS

1/8" CED and usually a step of .125" as well. I go 20k RPM's @ .40" IPS

The cutter cuts like butter with very good harmonics. For cooling I use the Vortex and spray WD-40 out of habbit and I probably don't even need to, habits die hard.

[jay_p]

Erik,
Could you elaborate more on your reference to the Vortex? Is this a chiller, or just compressed air? also, do you have a number on the Belin bits?

thanks

Jay

[wcsg]

Jay, here's a pic of the vortex

http://www.thesignsyndicate.com/forums/index.php?showtopic=1394

The Belin bits are tool#

33317 1/8"CED 1/4" Skank, 5/16" CEL
33635 1/4" CED. 5/8" CEL

They have a 3/16" but have yet to try that one.

I like the plastic/wood bits too, recently I changed over to downcut spiral for my 3/16" and thinner plastics, I use less double stick tape for hold down and less chance of movement.

[jay_p]

Thanks for the info Erik.

Jay

[routerman]

I recently tried the arizona vortex cool tool on my cnc router....keeps the bits cold and it is nice because there is no cruddy coolant to mess with and get all over the place.