Routering Aluminum Sheet

[analogman]

Hey all, I am wanting to router .080 6061 aluminum sheet (about 22" x 16") used for control boxes. There are quite a number of holes all over the sheet ranging from 0.125 to 1.00. I am using my data-cut machine with a dewalt router.

1) what would you suggest for an appropriate router bit for the larger holes? Suggested feed and speed?

2) any recommentations on cooling? I plan on getting a mist cooling system for this work.

3) and finally - how do I hold this puppy down? All the holes are through holes. I am more than happy to build a vacuum system, just not sure how to deal with through holes.

thanks!

[Cartierusm]

First off do you have a spoil board on your table. You'll need one for through holes bu the problem is the mist and wood don't mix. Mist is always a good idea for cutter life, but not good for wood. I do aluminum on my machine dry not coolant, you just have to watch the bit to make sure it doesn't load up. I would get a nice carbide 1/4" and 1/2" endmill for milling machines not router bits. Depending on how rigid your machine is I typicaly got pretty fast but super shallow cuts. Also remember when doing any operation to have the CAM do ramping (ramping is having the bit move back and forth slowly working in the workpiece instead of just plunging in). On aluminum I go .01-.03 depth of cut and 40 ipm feed and 10 ipm for plunge rate. I would go with .01" depth of cut first and see how it goes. To hold it down use some pieces of wood with a slot in it and then bolt it to the table of the router. Most people have tapped holes in their router tables so they can secure work to it. 2 on each side with a 1/4-20 screw and you'll be good, if you can't move it with heavy hand pressure then your golden. What I do is router a few of the holes I need then stop the router and screw in with wood screws and washers then finish the hole drilling or other operations in the piece. Then remove the clamps that are holding the edges of the piece, remember the screws you used in the holes that are already are holding it down, then run the outside program if you're finishing up the edges.

[analogman]

Cartierusm, thanks for the very detailed post - you have answered it all! Yes, I do have 1/4-20 holes every 4" or so and I will put down a spoil board. I suppose I can reuse the spoil board for multiple runs if I clamp the stock in the same position each time.

I would sure like to figure out how to use drip or mist, but I know what you mean about mizing it with wood - blech!

d1

[Cartierusm]

Just make sure to watch the bit, aluminum loads up real easily. Oh, make sure you get a 2 flute endmill, ones for aluminum are better.

[plcamp]

analogman -- another option would be to use your mister without the coolant. the airstream will help remove the chips from the work area thus preventing the cutter from re-cutting them. oh, note that your air supply must be large enough to keep up with the demand and that running the compressor will add some cost to your product.

PLCamp

[zenbot]

All of the previous posts had great advice. I would get an Amana tools aluminum-cutting router bit though. They work great for cutting aluminum on a cnc router.

[Cartierusm]

Zen, I forgot about those. I've never tried them but I'm sure they might be better than endmills because they are specifically made for aluminum cutting on a router. Good call. Although I'm not sure how much they are but you can get cheap endmills everywhere and if you dull it or break it who cares, but if the amana ones are $35-$60 it could be a pricer option.

[Nastyzen]

I sometimes use a soft wax stick on the end mill and even smear it along the cut line to get the speed up or on some finishing passes to get nice finish.It's even great on the band saw and greasing up the grinding wheel is a must.

[BobF]

I like the Onsrud super O flute for aluminum.
https://www.onsrud.com/xdoc/metal

[eloid]

the ultimate vaccum system by far...!

http://www.youtube.com/watch?v=SfvQo...layer_embedded

http://www.youtube.com/watch?v=X6hVL...layer_embedded

your could easly make this out of mdf or aluminum, protype a small vacumm table use this concept.

[analogman]

Thanks all for the great suggestions - this looks like it will be pretty straighforward.

[revwarguy]

Just wanted to say thanks to those who responded, as I have a similar task coming up when I get my table finished (assuming it ever gets finished.) Analogman, would you keep us posted on how your experience turns out?

Also, can anyone post some pictures of their more ambitious aluminum cuts done on your DIY router?

Thanks again,