1. Let suppose, for the sake of arguement I have a 60mm dia brass disc, approx 1mm thick. Around the periphery, approximately 3mm in from the edge, I wish to cut 400 slots, each 2mm radially and 0.23mm wide.

    To index the disc it will be mounted on a backing sheet of some description and attached to a stepper which will be 1/2 stepped to give 400 indexable locations.

    So what to cut with? PCB routing cutters can get close to that level but would need careful depth control to get a consistent width. I've seen MicroCarbide endmills at 0.2mm on the web, but how realistic is that?

    Laser, spark erosion, what?

  2. #2
    You want one of these

    http://cgi.ebay.co.uk/RDGTOOLS-3-HSS...mZ260440292094

    or better still one with a smaller OD so it doesn't wobble. these will cut your slot in one pass.
    John S -

  3. Good try John, but the slots have to be a controlled length, not right to the edge.

  4. #4
    Oops missed that bit.
    What about doing this on a 54mm disk and pressing a 3mm ring on afterwards ?
    John S -

  5. laser - I doubt they will cut copper alloys
    edm - yes but at a cost
    0.2mm milling cutter in a top-notch cnc - no problem
    0.2mm milling cutter in a converted drill/mill 1 or two notches then snap...

    How about photo-etching?
    Last edited by BillTodd; 09-09-2009 at 11:43 AM. Reason: typo foxed

  6. #6
    Laser will cut brass but the edge finish is $hit and at 0.23mm wide probably impossible.
    Spark eroder will do this no problem but you need a graphite or copper master and cutting this gives the same problems as cutting the slots.

    What is it for ? can the design be altered to suit a better method?
    John S -

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