Save my sanity - 1050 grade aluminium

[Isaac]

I cut some parts from 1050 the other week. Yes, it's a bit of a devil to cut but I found the slower the better... These are the parts I cut:

Attachment 12462

And here's a clip of the machine at work. (Yes, that is the alu sheet bending while getting spot drilled - I was feeling my way around the RPMs needed...)



And here are some cutting details - all very conservative:

Spot drill - 10k RPM
HSS Through Drill - 5k RPM
3mm 2 Flute Carbide Cutter - 10k RPM
1mm 2 Flute Carbide Cutter - 13k RPM
Plunge rates at around 0.75-1mm/sec
Feed rates no higher than 3.5mm/sec

WD40 - a must. The cutter squeals a bit without it...

Wal.

I'm getting somewhere now!

I dropped to 13k, 600mm/minute 0.75DOC with a 3mm single flute carbide and I'm getting a clean cut with fairly big C shaped swarf. It brought a tear to my eye ;)

Cheers guys!

[Wal]

I'm getting a clean cut with fairly big C shaped swarf. It brought a tear to my eye ;)

Ooo - safety goggles..!

Hehe, glad to hear that you've hit upon numbers that are working for you. Well done.

Wal.

[cropwell]

Cutting ali is better with an open flute, like these, which I use.
Sorotec - Werkzeuge

Moderate feed rates and spindle speeds give good results (even on my MD machine ) with a little bit of air to clear the chips and a drop of paraffin to cool and lubricate the cutter.