Thread: Shaping aluminium

I use my bandsaw it gives an accurate cut with practice and then sands on a disk sander easily and well.Also use a bobbin sander for internals finishing.
If you want accurate use a C and C Router service, most accurate and sharp cuts.

Have success Peter.

I use an engravers pantograph for milling holes, slots and other shapes in Al tube. It is excellent for repetition jobs and provides excellent finish using router blades for the cutting. I don't know if it would have the guts for 12mm though, it might work well as a finisher after removing most of the material quickly but roughly.

I'd rough it out as close as you can using jig or band saw, then use a good 1/2" shaft bearing guided edge trimming router bit. Carbide. Lots of kerosene or similar for lubricant. (Make an accurate template from some durable material to guide the bit...ideally aluminium, but sealed MDF will work too if not flooded with lubricant. Standard safety precautions apply and don't rush.

The chips are fluffy and small and get everywhere.

Greg

I am editing after the next post which is probably more to the point, but for the sake of a complete answer:

Carbide 1/2" bit speed should be around 20,000rpm, 3/4" bit 14,300 rpm based on speed of 2820 fpm which is recommended for the 5000, 6000 and 7000 series alloys.

Using the formula SFM X 3.82 divided by diameter

Also I read that lard oil is another lubricant for aluminium if you like that bacon smell in the shop.

Greg

Hi Tiger,
If you are turning out a lot of this in the same shape, it may be worth getting a quote for laser, plasma or water jet cutting by an engineering works. Once the CAD drawing is in their system each batch works out cheaper, and the accuracy is amazing, with very little cleanup needed.

Cheers,

Thanks, I have found the disc sander good enough although a bit slow, thanks to Penpal and others for responding. The CNC option is probably overkill for what I have in mind but something I would look at if I had the funds!