Do I need a band saw?

[Sonicmook56]

Ok, sorry if this is the wrong forum to post this in, but there does not seem to be much talk about band saws in general around here.

I need to make a bunch of panels out of 1.5"x0.125" 6061 extruded aluminum stock, Panels need to be square at 5.250" +/- .003" in length. Here is how I currently do it:

First I go to the local metal supplier and buy the extruded aluminum precut to 12" lengths and cut them in half with a hack saw leaving an awful edge. This takes time and makes my arm sore after cutting for 1/2 hour (I buy them this length because there technically scraps, therefore cheaper.)



then I stick the part in the mill to square off the end . This take time, mostly because I use screws as the hold down method in my jig.



then after the mill is done I check the part with a caliper to make sure it's within tolerances and put them aside for the next milling step.



I'm looking for advice on how to make this step faster and easer to do. I was thinking a small benchtop band saw would do the trick, like the Delta 9" or the Enco 14" as seen here:
http://www.use-enco.com/CGI/INPDFF?PMPAGE=551&PMCTLG=00

Then there is this one, that the NYCCNC guy picked up and modified.

http://www.ares-server.com/Ares/Ares...oduct&ID=82203

http://www.nyccnc.com/Herbie/HERBIES...DIY_Fence.html

(Why did you choose this model over another?)

question is, would one of these machines hold tolerances well when equipped with a fence and equipped with the right blade? what is the best blade and speed for 6061?

Then there is the Horrible Freight/Grizzly horizontal band saw for not much more. This model had a vice that could hold a whole pile of stock and cut threw them all in one pass.
http://www.harborfreight.com/cpi/cta...emnumber=93762 <--Looks like this one went way up in price?

http://www.grizzly.com/products/4-x-...-Bandsaw/G0622 <-- Cheaper than Harbor

Would a vertical saw be better than a horizontal? For now I only wish to cut this size of extruded aluminum. I've never used a band saw so I have no idea what I'm doing.

~B

[dang]

The short answer is yes, you need a bandsaw.

Check out Yahoo's 4x6 Bandsaw group. There are a bunch of hopped up saws there. For your application I'd think about a bar feeding mechanism and a coolant system as well.

Here are some photos of that Bar Feeder. Wish I had one.

[blackbeard52]

I agree that you need a bandsaw or cutoff saw to be more correct... however the tolerances you request for the saw may be disappointing. it looks like you may have to still face the ends but not as much material needs to be removed. so a finish pass should be all that is needed. Also I have seen the cutoff saws used that I refer to as a trim saw used in wood. a blade is now available to cut nonferrous materials like Aluminum. Those are also available at Harbor freight or most tools suppliers. here are some links http://www.harborfreight.com/cpi/cta...emnumber=44829
http://www.harborfreight.com/cpi/cta...temnumber=1624

[High Seas]

Sonicmook56 - If those were timber, I wouldn't have even considered a bandsaw -- looks like a job for a radial arm with a jig - or a mitersaw/cut-off saw.
I'd cut those on my miter/chop using a metal blade. New blades way cheaper than a new tool --- But then sometimes any excuse for a new tool is a good one!
Jim

[Geof]

Maybe I am missing something?

Why not get your supplier to cut them to 5-3/8" and then all you need to do is face the ends.

No matter how you cut them, and High Seas' suggestion is the way to go, you will never get your required tolerance from a saw.

Maybe I should qualify that; you could get a multithousand dollar cold saw that would meet your tolerance but that is probably not going to happen.

[blackbeard52]

Geof
I think he is getting them as drops... so a secondary cut would raise the costs of the material greatly. As I metioned and I agree with you, There is still going to be a secondary operation to machine to tolerance.

Bob

[Geof]

Originally Posted by blackbeard52 Geof I think he is getting them as drops... so a secondary cut would raise the costs of the material greatly...Bob

How large is 'greatly'?

Time is money and it is necessary to weigh the value of your time in cutting pieces against the extra cost of buying them precut. Sometimes it is less expensive to pay more money.

[Hirudin]

An idea from a newbie...

If you cut them to say 5.3xx" with a band saw (or anything else really) you could probably mill several of them down to 2.250" at once.