Cutting Aluminum

[darylprice]

I just finished biulding my first Router. I have a Servo system from Camtronics with 1100oz x-y axis and 400oz for Z. I need to make aluminum parts out of 1/16" 6061 Aluminum. I purchased a Porter Cable 690 router with variable 8 to 25,000 rpms, but it is cutting too fast for my end mills I am using.
Can anyone tell me good combination of Router and End Mills that will work with somewhat better than it is now. No matter how slow I cut it seems to be burning up my end mills and giving me a really bad looking cut. I am hoping I just need a better set of End Mills, and if so what should I get and where?

I will appreciate as much information as possible. I hope to get pictures of my machine online soon, unfortunately, just like everyone else, I have to work for a living!!

Daryl Price

[Geof]

What size end mill are you using? A 1/4" carbide two flute with 45 degree helix (GAR 242 I think) will work fine at 10,000 rpm in 6061 running at a feed of about 50 ipm. You will need cutting fluid but on 1/16" material you can get away with just painting it along the intended cut line.

[randyf1965]

http://www.endmill.com/pages/training/spdfeed.htm

You need to figure out how fast you need feed for the size end mill and the rpm

[Bruggles]

You definatly ned a carbide cutter. I have had good luck with the duramill carbide aluminum cutters in 1/4 inch. I spin the router at about 16000 rpm, and use a-1 for cutting fluid. Just play a bit with your feeds to get the best results, and if you go to the endmill manufacturers web page they can give you the specs, so you can figure out your feed rate etc. Also your cut will not be clean if your machine is not ridgid, it sounds like your motors are plenty robust, but I don't know about the rest of your machine. If it is really ridged you sould be able to spin one of those duramill cutters at like 25,000 rpms and just fly through the material. An a-1 or wd-40 mist would definatly help out, with the finish, and so your cutter doesn't gall up and break, or just melt through your aluminum. I can cut 1/4 inch aluminum nearly the entire cutter width and full depth with my router on a router table with a template at 16,000rpm with a-9, and get shiny smooth surface finishes if I climb mill on the last pass. I hope that helps out. an oil of some sort is definatly necessary, air doesn't help, unless it is just to get the oil to the cutter.

[darylprice]

Originally Posted by Geof What size end mill are you using? A 1/4" carbide two flute with 45 degree helix (GAR 242 I think) will work fine at 10,000 rpm in 6061 running at a feed of about 50 ipm. You will need cutting fluid but on 1/16" material you can get away with just painting it along the intended cut line.

Thank you this helps alot

[ger21]

Try www.onsrud.com They have an entire catalog of high quality router bits designed to cut aluminum.

[Bruggles]

Those onsrud bits look nice, but they are super expensive. Check out www.duramill.com, there aluminum cutters work great, but are less than $30 for a 1/4 inch coated cutter, where it looked like onsrud was around $85. When I said a-1 cutting fluid I meant A-9, it is amazing stuff, and it is not that expensive. with the duramill you can run at 25,000 rpm and 100ipm if your machine is rigid enough and you can get some lube to it.

[darylprice]

Originally Posted by Bruggles Those onsrud bits look nice, but they are super expensive. Check out www.duramill.com, there aluminum cutters work great, but are less than $30 for a 1/4 inch coated cutter, where it looked like onsrud was around $85. When I said a-1 cutting fluid I meant A-9, it is amazing stuff, and it is not that expensive. with the duramill you can run at 25,000 rpm and 100ipm if your machine is rigid enough and you can get some lube to it.

Thank you I have already oredered from Duramill. Great place thank you very much. I am not sure I can run at 100ipm but probably 50 anyway. My machine is quite rigid. Thanks again