How to machine ends of THK type linear rail

[SES1]

Hi,
I have purchased some surplus linear rail that is all cut to the same length.
Does anyone have experience in machining the ends of THK type linear rail to mate?
Thanks for your help.

[Mr_bossman]

One thing to remember is these rails are very hard material.One way is to use a quick cut saw,another is EDM wire them or grind on a surface grinder.


Hope this helps.....

[LeeWay]

I burned up one bandsaw blade and three diamond wheels on a dremel making one cut. Then dressed both ends on a belt sander. The end result was fine, but took about an hour to slice through. Chop saw is on my list of things to buy. I have one for wood, but they really aren't made for metals other than aluminum possibly with the right blade.

[SES1]

Thanks for the response Mr Bossman and LeeWay. These rails are hard for sure. We've been able to cut them with a chop saw ( using coolant also) and machine the ends with a carbide mill, but we aren't sure about the edges and tolerances. My guess is the factory bevels the edges somewhat to eliminate burrs. We stoned the edges slightly, but there is still a slight resistance when the bearing makes the transistion between rails. Maybe the seal is catching, not sure at this point.