Slitting-slotting saws

[Vern Smith]

I need to cut some slots in 6061 T6. I've never used a saw before and could use lots of advice. MSC lists both slitting and slotting saws, carbide teeth and solid carbide, some with key ways, most without.

I need to cut two slots, one .060 wide and the other .261. The saws listed for nonferrous have only 4 or 6 teeth on a 3" diameter. Is there an arbor ( mfg.?) that will clamp down hard enough to keep a 3" saw from moving? Suggestions on speeds, feeds, and DOC appreciated. Also alternative sources to MSC.

Vern

[tobyaxis]

A few rules on Sliting saws.

1) be sure to have at least 2 teeth in the material at the same time.
2) lots of Coolant
3) Feeds and speeds are very light like .0005 per tooth

ex. 3 inch diameter 27 teeth would be around 100 to 150 rpm and 1.35 Inches Per Minute. Carbide is about 10% higher in feeds and speeds.

[Chuck Reamer]

How deep are you slotting, for very shallow slots I have used a boring bar with a groving insert in it. Works well but you are limited on depth.

[Vern Smith]

The .060 wide slot will be shallow, around .100 to .125, The .261 will be .700 deep. How well do the saws behave when stepped over? As an example, using a .125 thich blade to cut the .261 slot.

Thanks for the input.

Vern

[tobyaxis]

Originally Posted by Vern Smith The .060 wide slot will be shallow, around .100 to .125, The .261 will be .700 deep. How well do the saws behave when stepped over? As an example, using a .125 thich blade to cut the .261 slot. Thanks for the input. Vern

If that is what you would like to do, make your cut in three passes. Meaning you will cut the Middle first then two finish passes one top and one bottom. This should work fine. If you get Chatter slow the RPM a little and increase the feed a little. I'm talking like 5% to 10%, nothing radical. If you over ride too much your slot cutter will flex and most likely break or dull causing failure.

[gizmo_454]

This being my first post, I would just like to say hello to everyone on the forum.

On the slotting subject, we bought a Mini Mill last April specifically for drilling and slotting 40000 parts. The parts are made from 12L14. The diameter of the part where the slot is located is 0.495". Slot depth is almost 1" and the width is 0.191".

The slotting saw that we use is a 4", 10 tooth, carbide tipped, 0.250" wide saw that we cut down to our required diameter. Taking full depth of cut, we run the saw at 600 RPM and are feeding it at 15ipm. That's about 0.0025 per tooth load, in steel. This has been successful for close to a year now.

We would really like to have a saw with 20-24 teeth that is carbide tipped, but without having one custom made, we are out of luck.

Anyway, I would think you could go more feed and speed in aluminum. I was told that I could theoretically go upward of 1000 RPM and 30ipm for my situation. That sounded scary to me.

As far as holders go, the holder we use is a Bison "semi-flush" arbor. The saw does not move. It's pretty sturdy. Cost is about $110 US.

I hope this gives you an idea of what you may be able to achieve.

Gizmo

[tobyaxis]

Originally Posted by gizmo_454 We would really like to have a saw with 20-24 teeth that is carbide tipped, but without having one custom made, we are out of luck.

Have you checked out Moon Cutter? They might have what you want.

http://www.mooncutter.com/

BTW: I run a 2.5 Diameter by .25 Wide at 1500 RPM and 35.0 IPM in 7075 Aluminum. It's a 1.5" Diameter Arbor and the Machine is a CAT50 Taper Matsuura.

[gizmo_454]

Thanks for the tidbit. I just looked through their online catalog and didn't see anything more than 8 tooth on a 4 inch cutter. I know HSS cutters have many more teeth, but my Mini Mill doesn't have the torque needed to run them at the lower SFM.

[tobyaxis]

Originally Posted by gizmo_454 Thanks for the tidbit. I just looked through their online catalog and didn't see anything more than 8 tooth on a 4 inch cutter. I know HSS cutters have many more teeth, but my Mini Mill doesn't have the torque needed to run them at the lower SFM.

HSS has lower cutting forces than Carbide, but I understand your dilema. Sorry they didn't have anything for you. Maybe there is another place that will.

Cheers!!!!!!

Try These Guys
http://www.hannibalcarbide.com/
http://www.iscar.com/
http://www.secotools.com/template/start.asp?id=2181
http://www1.mscdirect.com/cgi/nnsrhm

[mulcher]

you should try milling it.

[tobyaxis]

Originally Posted by gizmo_454 Thanks for the tidbit. I just looked through their online catalog and didn't see anything more than 8 tooth on a 4 inch cutter. I know HSS cutters have many more teeth, but my Mini Mill doesn't have the torque needed to run them at the lower SFM.

When you say Mini Mill, do you mean that you have a CAT40 or an R8 Spindle Taper???? What Machine do you have?????

[jackson]

Originally Posted by Vern Smith I need to cut some slots in 6061 T6. I've never used a saw before and could use lots of advice. MSC lists both slitting and slotting saws, carbide teeth and solid carbide, some with key ways, most without. I need to cut two slots, one .060 wide and the other .261. The saws listed for nonferrous have only 4 or 6 teeth on a 3" diameter. Is there an arbor ( mfg.?) that will clamp down hard enough to keep a 3" saw from moving? Suggestions on speeds, feeds, and DOC appreciated. Also alternative sources to MSC. Vern

This is what i run mine at on 6061 one pass the saw is HSS works great
N5
(T5 3" SLOT SAW 3/32 THICK)
G90S1000M03
G00X-1.Y-2.65T1
G43H5Z.5M08
G01Z-1.1F25.
Y-1.7F6.
X-3.15
Y-2.95F25.
G00Z6.M09
X-5.Y6.
G91G28Z0
M01
M06
M99