What is the best method for boring large holes in aluminium bar?

[Blakelidge]

Hi,

I have a Taig C4 lathe (no mill yet) I am looking to use 2" OD aluminium rod - 6062-t6 & 6082 - T6 From the rod, I will be cutting approx 50mm and I need to drill/bore through this depth removing around 40mm, basically, this will leave me with a tube that has a 5mm wall.

Clearly, that is a large amount to remove and currently I am initially boring out holes from a small 3mm diameter up to around 1" then I take that up to 40mm using my boring bar. As you can appreciate that is a slow process and I was wondering if there was a more efficient method of removing such a large amount of stock?

[LeeWay]

I think that is the way it's done.
You may be able to eliminate the drilling portion by buying suitable tube to start with rather than rod.

[davereagan]

Whose part is it? Why would someone engineer something so close in size to a piece of tubing that requires machining from a solid?

[ger21]

Yeah, why not by 1/4" wall 2" tube?

[Geof]

Sometimes a good reason to bore from solid is because you can buy a short length. Many suppliers do not carry heavy wall aluminum tubing, sometimes when they do it is not 6061 but is a structural alloy.

[ger21]

McMaster Carr has it in 12" lengths. Probably not the cheapest place, but it's available.

[Geof]

McMaster Carr has it in 12" lengths. Probably not the cheapest place, but it's available.

In the UK?

[ger21]

The little details always get you. No, I guess not in the UK.

[Geof]

The little details always get you. No, I guess not in the UK.

I did a second read of the first post and found the details do indeed get you; it mentions 6062 and 6083 which arestructural alloys.

[Blakelidge]

Hi again,

I did consider tube, that would be an ideal solution, but it seems 2" tube with 1/4" wall does not exist, seems suppliers go 2" tube (3.6mm wall) and the next size up is 2.5" x 1/4" wall, unfortunately the 2.5" inner diameter is too wide I.E. 63.5mm od x 6.35mm wall this leaves me with a 50.8 ID, I need a 48.8 ID

I was only able to figure I would need to machine from solid to get the needed diameter, unless anyone knows another method? as I am still pretty novice at this.

Essentially I need to mate two pieces together, first is 2" tube machined to 48.8mm finish, I then need a bezel with a OD finish of 53.8 (from 2 1/4" rod) and ID of 48.8 so this part will be a friction fit over the first part, unfortunately I'm stuck with the 48.8mm of the first part as this is dictated by the part's use.

I have a mate who does casting and he has offered to cast me some rings, in an effort to avoid so much material removal for me, but I understand castings will not anodise properly, I already have my issues with the alloy I'm using and anodising, but finding 6063 - t6, which I am advised is much more suited to anodising, is not avaialabe in anything like the sizes I need. Haha, life is so tough. Shame I can't make the parts out of plastic or something, but as the part as a role to play in heatsinking this too is a no no. I welcome myself to the world of engineering & design, fun but challenging - a top hobby

[davereagan]

I don't see why you couldn't find tube in the UK. Below is my favorite aluminum supplier out of Akron, OH. They use UPS, so I don't see why they wouldn't ship to you. They even have 2" tube in 6061 with 1/8" wall, so you would have your size in no time and spend half as much to begin with even compared to 1/4" wall. Is the paradox that we use "English" units and now the UK goes in metric sizing? LOL.


http://www.clintonaluminum.com/Pivot...=34&Search.y=4

[davereagan]

If they turned you down, I would be happy to forward the stock to you if you purchased it from them with a Mastercard. Not sure what your time frame is either.