Thread: Machinability of 6060 aluminium?

I find with any ally chip removal is key. If they hang around they can get hot and i have had them melt on to cutters. I normally spray some WD or kero on the piece first then use air to clear the chips as it cuts. I have had zero experience outside plain ally though.

Ew

ethonol works as a cutting fluid. carbide is great to

I use kero in a spray bottle or WD40 if I can reach it first.

Ben.

I use inox as a lubricant I agree with Ueee use air to clear the chips

I use kero as well ! I apply it with a brush and brush the chips away since I've no air supply... Yet !

Nice one fellas! I will give it a go then.

I'm changing it up a little and cutting up a gasket to make a track. It's a much larger surface area and a whole lot faster to make. But I will still need to chop it all up and dress the edges.

Actually, I have to cut the stock to suit. I'm thinking an aluminium cutting blade on the table saw to rip it to size. My neighbour has a 'dual saw' I might borrow. It comes with lube sticks for cutting ally. I can't bring myself to buy one as this is the first time I think I could have used it...they seem a little Mickey Mouse to me.

6060 will machine fine, just keep the chips out of the way as others have suggested.
As far as lubricant goes, CRC/Inox/WD40/Kero and possibly Diesel would be fine as is soluble oil/water mix. I add Diesel as it is cheaper than Kero and I reckon its properties should be similar, plus I like the smell of it.
Something to watch out for with the machinable grades of ally, is the fact that many are not weldable. A past employer of mine found that out the hard way, having invested a large amount of time welding hinge bosses into the bow doors of a car ferry, only to have them crack out as they cooled. Several $1000 later, new bosses made, old ones removed, new ones welded in.

Originally Posted by Ben Dono

Nice one fellas! I will give it a go then.

I'm changing it up a little and cutting up a gasket to make a track. It's a much larger surface area and a whole lot faster to make. But I will still need to chop it all up and dress the edges.

Actually, I have to cut the stock to suit. I'm thinking an aluminium cutting blade on the table saw to rip it to size. My neighbour has a 'dual saw' I might borrow. It comes with lube sticks for cutting ally. I can't bring myself to buy one as this is the first time I think I could have used it...they seem a little Mickey Mouse to me.

Hi Ben,
FWIW I often use my 10" 80 tooth TC table saw to cut aluminium, both sheet and bar. I've cut 20mm thick sheet and 4" round bar on mine. It runs at 2800 rpm and requires wax or some other lubricant. Just take it steady and don't push it too hard. What happens is the alloy expands very rapidly and grabs the blade if you do. This stalls the motor on mine, which unless you get it switched off pretty quick will rapidly burn out the motor.

Bloody good point Baron! I didn't think of that.
I have four 6mm plates I have to rip down to 150mm from 160mm. I might be lucky and it will warp away from the kerf...maybe. I will take some care with it now though!