CNC .040 aluminum tricks

[Router Lady]

Hi Guys I need your help!!
I run a Gerber Sabre 408 CNC router table.
I have routed .040 aluminum in the past and have used a 2 flute upwards spiral bit and run the router at 50 IPM @ 19,000 RPM I need to run the job faster. Any help you could give with this would be great. I also need great edges that will need no filling .

Thanks for you help
Carrie

[Matt@RFR]

Carrie, just switching to a 3 flute endmill will bump your feedrate up to around 85ipm while keeping the same chipload you have now. Who knows, maybe on such thin material a 4 flute (or more?) might not load up. Try it. The worst that should happen is you break the endmill.

Is 19,000rpm your max?

[MFassler]

what size cutter are you using? for those speeds id use as small a cutter as possible so there will be less tool pressure.

[Router Lady]

My max RPM is 24000

I'm using a 1/4" dia. bit because I also have 1/4" dia holes I have to drill and I don't have a atuomatic tool changer so takes to long to change from a smaller bit to a 1/4" bit.

Thanks for your help if you have any more Ideas let me know but I will try these for now.

Thanks guys
carrie

[thescenicroute]

Do you have a mister on your router? I use water dilluted cutting oil through a mister whenever I cut metal. I can even cut steel with my dinky 5.5 hp routers as long as i have a good chip and I keep the bit and material cool. McMaster Carr sells a great inexpensive option. Part # 10445K34

Smaller cutters are going to take too long and bumping up your rpms is going to get too hot and your going to start to reweld. A bigger bit would got a faster cut time, maybe jump up to 3/8" if your part allows that kind of radius.

I can't stress enough using coolant when cutting metal. Makes all the difference in the world, even on thin sheets.