Aluminium cutting

[routercnc]

Hi Bush flyer,

I recently cut some elongated slots with a 3mm carbide bit without any problems. I don't use the 3mm cutter much (tend to use 6mm) so haven't experimented but the following settings worked OK:

DOC 0.3mm
rpm 12,000
300mm/min feedrate
30mm/min plunge rate

The 4 slots were 5mm wide, 15mm long, and 10mm deep (other side is pocketed 10mm). See photos below.


(I was actually surfacing the whole part in this photo - hence the 6mm cutter in the collet, not 3mm, but you can see the slots I was refering to)

I flooded the holes with duck oil as soon as cutting started. There was no smoke, no screeching, just a soup of very small chippings swirling around in the pocket as the cutter did it's job.

[EddyCurrent]

Hi Bush flyer,

I recently cut some elongated slots with a 3mm carbide bit without any problems.

What's the cutter details ? e.g. single flute, up spiral

Edit: This might seem a daft question but to me the thread is going round in a circle until Bush Flyer uses a cutter of the same type and most importantly, brand, that others are using when they suggest cutting parameters. The difference between a good cutter and a bad one is chalk and cheese.

[Bush Flyer]

Hi Routercnc,
Thanks for the quick reply, That's just what I wanted, your setting for slotting aluminium I will try again tomorrow with that settings. Would it be possible that you could also tell me the settings you are using with your 6mm single flute end mill as well I have 25mm thick aluminium to cut so am thinking I will get a few 6mm end mills.

[magicniner]

I bought some cheap 3mm single flute cutters from Ebay, whilst the cutters themselves are good the initial edge applied to them is a little random, fortunately the single flute cutters are very easy to hand sharpen and and a quick touch-up on a diamond wheel is all they needed to get them cutting cleanly. They're not listed as suitable for Aluminium but I've used one on Brass, Bronze, Aluminium and Titanium and I'm still on the first one of a pack of 10 ;-)

- Nick

[Bush Flyer]

We have success, Using the settings from routercnc I was able to cut aluminium without breaking the end mill or blunting the end mill. Now just to fine tune, I used a zig zag plunge from zero Z axis height and it was too slow I think at the low plunge depth I will try it without the zig zag or increase the plunge rate and keep the zig zag, Now all I have got to do is the same for a 6mm end mill. Thanks again routercnc.

[routercnc]

Glad it helped.

3mm bit was carbide 2 flute slot drill from 'bargain tooling' on e-bay:
3MM CARBIDE SLOT DRILL / CUTTER 2 FLUTE *NEW* | eBay

I don't usually cut much aluminium, so am not an expert, but I have been cutting a fair bit recently for the upgrade parts. The setup I'm using is as below. This is what works on my machine, but no guarantee for yours:

e-bay again from bargain tooling. Can't find link to original part I bought but similar to this:
6MM CARBIDE SLOT DRILL / CUTTER 2 FLUTE *NEW* | eBay
dia: 6mm
material: carbide
flutes: 2

feedrate: 800mm/min
(it feels like it could take 900-1000mm/min which is a better load, but running on 26V machine concerned about stalling/missing steps. Still waiting for new drivers . . . )

plunge rate: 150mm/min

DOC: 1mm
(tried 1.5mm today and tends to squeal / resonate - upgrade parts should improve things)

WOC: 6mm

spindle speed: 12000rpm

[AGTM]

Hi All

I am reading here the discussion about the aluminium cutters. I also checked the links to eBay.
Yes, this price is good, but I would recommend something better. Check this out: http://www.agtmcarbide.co.nz/product/aue-0603/. These cutters are great, just as good as Iscar, but a lot more valuable. These tools can do DOC: 2.5D and WOC: 1D.
Not bad. Here is something more: http://www.agtmcarbide.co.nz/speed-tiger-cutting-tests/

[Bush Flyer]

That's great, just sent an order to ebay for some 6mm end mills. Thanks for recommending the seller routercnc, I appreciate your help and I will test it with the setting you have recommended.