how can i do this ?

[max_imum2000]

can anyone tell me how can i carve a grove like this one (leaft upper side of pic), this is a half circular grove (about 5mm diameter) in an aluminum extruded block (1meter in length) , the half circle is made in a 30degree inclination.
i have access to a shop with manual machines (no cnc)

[ViperTX]

Ah.....well create a fixture that produces the 30 degree angle in relationship to the ball end mill of the proper diameter....

[Karl_T]

Just another possibility for you.

Grind a fly cutter to the shape you need, Then you can clamp flat on the mill table against a backstop. Release and reclamp for next pass.

Karl

[max_imum2000]

can i shape a girder wheel to the shape i want , then let it metal pass through it ?
if so , how can i shape the wheel in the first place ?

[Ken_Shea]

What is the depth of the 5mm hole and angle ?

Can't see for sure looking at the picture.

Ken

[One of Many]

Originally Posted by max_imum2000 can i shape a girder wheel to the shape i want , then let it metal pass through it ? if so , how can i shape the wheel in the first place ?

You cannot grind aluminum in that way. It will stick to the wheel and can explode when it becomes out of balance.

Looking at the profile, Do I see an angle the the radius is cut into?

If so, is the radius cut perpendicular to that surface?

Point being that the head on the mill could be tilted to cut the radius to the angle with a full radius wheel cutter. Keeping the part flat on the table against some pins makes it easy to slide the part down and continue the cut. Positioning the cutter in reference to the part at some point off the part can be troublesome, but with attention to detail its no big deal.

Tilting the part when it needs to be repositioned over the cut length can make re-alignment difficult without a decent fixture.

See the examples drawn. It depends on how critical the shape and location really needs to be.

DC

[max_imum2000]

here is a side view drawing
well the part should be as accurate as possible
and yes the radius is perp to the angle and it is all the way along the length

does these methods gives a smooth surface ?
also can i shape a cutter to the exact same dimenstion and cut it using a shaping machine ?
is so , then how can i shape the cutter that accurate ? i mean make a perfect half circule in the cutter ?
your help are much appricated

[One of Many]

Originally Posted by max_imum2000 does these methods gives a smooth surface ?

The finish will be a result of the feeds and speeds of your cut and chosen method.

Originally Posted by max_imum2000 also can i shape a cutter to the exact same dimenstion and cut it using a shaping machine ? is so , then how can i shape the cutter that accurate ? i mean make a perfect half circule in the cutter ? your help are much appricated

The term "shaping machine" can have multiple definitions. If you have a single tooth cutter stroking shaper, there is still the need to hold and cut 1 meter in length. Not very realistic if the stroke of the shaper were shorter than 1 meter. In the States, we would call this a planer/shaper. I don't think they like ending a cut abruptly.

Some shaping machines are used to cut a profile into wood molding trim. These do use a rotary cutter similar to routers, but can be made up with stacked cutters to modify the shape as desired. It may be possible to cut aluminum in steps, but not all in one pass as wood is done. Lots of cutting oil would keep the chips from sticking to the cutter since these machines are very high RPM. The problems will be the ability to hold the part solid while feeding it through and then keeping the feed consistant to get a good finish. It can work with exreme care if only cutting the radius. If you need to cut the angle too, it should be done in seperate operations. From a safety stand point, I'd consider this as a last resort.

The radius being perpendicular to the angle forces a rotary cutter option to spin on the axis parallel to the angle plane or a ball nose cutter perpendicular to that plane. A single tooth cutting machine will need the part tilted to feed in one of the shapers axis into the radius center line.

If you have a local cutter grinder, it would be best to have any profile cutter custom made. A single tooth cutter can be hand ground and used in a fly cutter as has been mentioned in another post offering. It is just really slow!



DC