Tips for cutting 1050 aluminium

[Clive S]

but I've since cut a 200mm pocket 1.5mm deep into it (set the bed for Z0 rather than the Z-1.5mm I wanted)

You could make the pocket a little deeper and wider and then make a plug to go in it and glue it in position and re skim the bed.

[d4cnc]

If I wanted to use a 2mm cutter or even a 1mm cutter (obviously after a lot more practice as I'm sure I'd break them just by looking at them at this stage), how would that affect things? Presumably, the smaller the bit, the slower the feed.. and higher the spindle speed? It would be nice to get some tighter inside radiuses. (radii?)

You could make the pocket a little deeper and wider and then make a plug to go in it and glue it in position and re skim the bed.

Awesome idea! Thanks for the tip!

[Davek0974]

Possibly try
2mm, 1.5mm DOC, slotting, single flute, 24,000rpm, 120mm/min
1mm, 0.5mm DOC, slotting, single flute, 24,000rpm, 54mm/min

I have not gone that low yet though;)

[d4cnc]

Many thanks again. I've not been brave enough yet to try the 2mm cuts but will do later.. (I want some 2.2mm holes)


When it comes to work holding the sheet of aluminium and taping it down with carpet tape, what does everyone do with the protective backing?
Does that become the top as you cut through it? While the otherside is stuck down?
Or do you stick the carpet tape to the protective backing side ?
Or do you remove the protective backing altogther?

[Davek0974]

I always remove the film on both sides, the top layer gets in the way of the coolant/air i've found.

[JAZZCNC]

When it comes to work holding the sheet of aluminium and taping it down with carpet tape, what does everyone do with the protective backing?

On the lower side I leave film on if in good condition as it makes getting the tape off easier. On top surface then I tend to take it.

[d4cnc]

After a little experiment, I settled on sticking it on the film on the underside too. Worked great! Stuck strong. Easy to remove from MDF & aluminium. I used the Dial brand one from B&Q..

I tried the 2mm cutter on the settings above on some 2.2mm holes, and all seemed ok. I used a steeper angle helix this time and the chips certainly do fly like that!

I just did 1 pass.. am I right in thinking that due to this, the accuracy isn't great?
eg. some holes I can fit a 2.2mm drill bit in nicely.. others are too tight..
If I wanted it more accurate and repeatable, I'd have to pocket the holes at Ø2mm and then do a contour finish pass to enlarge to exactly 2.2mm?

[Davek0974]

Generally yes, a roughing pass leaving 0.1mm or so then a finish pass is best, i find it works well.