http://aluminium.matter.org.uk/conte...eid=2144416345

Its very difficult to say the exact cutting force, having in mind it will vary with your tool sharpness, type, teeth count,rake angle,the type of aluminum, feed, rigidity of the machine.


Better use your common sense. Download and use the spread sheets here from the forum to calculate the machine stiffness at different points, use HSMAdviser or GWizard to calculate spindle HP and deflection at different settings. Make up your mind and choose what to do further.


But i still don't get why you dig so deep. Its so simple. You want to do all up to aluminum- make a router. You want to do iron, steel and so - make mill. Once you decide that, its a matter of choosing the design that fits you and realize it.

I don't see reason fitting mill head to router. Cause once you start that, you will finish with a mill.



Your initial design was spot on. Your gantry was weak. Fit a gantry similar to my second build/i am doing right now/ and i assure you you will reap through aluminum like butter. The yellow router i build /look signature/ reaps through 1mm of aluminum without turning on the spindle , like a knife passes through butter, without feeling it at all. Or follow Johnathans design where the gantry is split in 2 and the z is inside. That are proven designs that will work very well. A well build machine will hold better tolerances than cheap chinese mill.

You will very unlikely use 12mm bits with aluminum. Most possibly 3mm and 6mm. Cause aluminum is expensive to waste it with 12mm tools.


Not that i don't believe that for a first build you will not make it. I just know how much time a very good design needs. Mistake here and there will cripple considerably the capacity of the machine. Talking about machine made for metals i mean. Aluminum or no. I for once want somebody to make the mill as i envisioned the column in the suggested post. If you feel confident build the mill, it would be cheaper than suggested if you build the frame yourself. Hell, once i finish that big trunk i am building now, will build myself a mill.