How to prevent cutting alumunium from clogging ?

[Calico]

I use 3mm diameter of tools to cut alumunium with 1mm depth, feedrate 40 (metric)
I use Sherline mill CNC and Mach3.

what ever I use the feedrate and rpm still give me the clogging.
that alumunium is the problem, I use liquid for cutting alumn. but no luck.

can anyone share any tips trick for this kind of cutting ?
this alumn is 5052 or something, not 7075, I have no problem with 7075.

cal

[dertsap]

spray a little wd-40 or varsol

[mxtras]

What is your spindle RPM and how many flutes does the cutter have?

Scott

[lerman]

To answer a question you didn't ask, you can remove the aluminum that has welded itself to the tool by soaking it in lye. Add some Drano to a container of water and soak the tool for a few hours. (Don't use an aluminum container.) Wear safety glasses, and follow all precautions on the Drano container. Be careful.

It works like a champ and doesn't damage the tool.

Ken

[mxtras]

Good advise, Ken.

Trying to dig the AL out of the flutes usually ends up with a damaged end mill or a trip to the doctor.

Scott

[NC Cams]

WE-40 and/or especially Dexron ATF are quite good for preventing aluminum from adhering to cutting tools and/or carbide burrs during cutting or machining operations. Neither is that caustic either.

[Calico]

Thanks guys,
I use 4 flutes and 2800 RPM.

I will try WD40 and Drano, what the hell Drano ? anyway... I don;t think I can find the guy name "drano" here in Indonesia but I will google..

so ... I have couple options here, but I try WD40 first since that guy is all over the world.

actually I use special liquid for alumunium to get the cutting better and make the tool life longer, forgot the name.

my conclusion here is it's no problem cutting with 3mm diameter tool with 4 flutes as long as you know how to do it right ?
I meant clogging is the only problem.

I broke 3 of them

thank you all
cal

[Geof]

Originally Posted by Calico Thanks guys, I use 4 flutes and 2800 RPM....

If you can get two flute cutters and go much much faster than 2800rpm I would try that. 5052 alloy is very bad for machining; it is too soft so the chips do not cut off nicely they jam up and wedge into the flutes. With a two flute cutter there is more space and they do not jam so easily. Also maybre go with a slower feed.

Originally Posted by Calico ...I will try WD40 and Drano, what the hell Drano ? anyway... I don;t think I can find the guy name "drano" here in Indonesia but I will google....

Drano is only to use for getting the aluminum out of the cutter if it is jammed up very tight; do not use Drano on the machine. Drano is a very strong alkali, mostly just Sodium Hydroxide (NaOH). Aluminum will dissolve in a strong alkali but High Speed Steel is not affected. Problem is; skin, muscle and bone will also dissolve in strong alkali so much care is needed.

[Calico]

thank again


cal

[mxtras]

You can also use a powerful, directed stream of air to keep the chips from clogging up in the flutes. I think the main problem you are dealing with is chip evacuation.

Scott

[msomerville]

I think the number of flutes is your main problem. I have used kerosene for cutting aluminum or a mixture of kero and oil. I have been checking out these vortex tubes and they have differents models that do slightly different things, but the one model can be set to blow compressed air out at -50 degrees all with no moving parts just compressed air. This is something I am checking out so I can't tell you how it will work for your application.

[lerman]

Hilsch (sp?) vortex tubes require lots of air. They are expensive to run (but cheap to buy).