Cutting a curved shape from a block of aluminum

[Neale]

So, at risk of prolonging the Muppet show. how would other people do this? In wood, I would probably throw a quick CAD model together in something like Fusion360, produce an STL model from it, then throw it at Vectric Cut3D to produce toolpaths. Rough with flat-ended cutters, then finish with whatever largest radius ball-end milling cutter I could find in the box. F360 could probably produce the toolpaths as well but I haven't played with the CAM stuff in it yet. Depending on finish required, probably end up with sandpaper wrapped round a dowel...

In aluminium, depends on what it's going to be used for. Clearance? Finish not so important so might do similar to above. Bearing surface? Try to rig up something on the vertical mill and use a large-radius boring bar of some kind. Not CAD but geometrically better? Good finish needed for cosmetic reasons but accuracy not so important? Maybe use "wood" technique and then find a way to file/polish out the ridges?

[eljainc]

The Muppet show....love it!!

Anyways, the wood prototype is basically that...a prototype, to prove that the part can be made. The aluminum part will basically "hug" the outside of a round metal pot
which will allow the other side to conduct heat from a peltier cooling/heating device. That is the reason for the curved part. I somewhat agree with you regarding the vertical mill and using a boring bar. We just cannot visualize it. We do have a Grizzly Mill....with indexing: G0619 6x21 vertical mill. We've never done anything with a boring bar...an idea to possibly try. Our finish required is not super important...just can't have a real rough finish or the part will not have great contact with the pot and the conductivity will not be as efficient.

[Rufe0]

The Muppet show....love it!!

Anyways, the wood prototype is basically that...a prototype, to prove that the part can be made. The aluminum part will basically "hug" the outside of a round metal pot
which will allow the other side to conduct heat from a peltier cooling/heating device. That is the reason for the curved part. I somewhat agree with you regarding the vertical mill and using a boring bar. We just cannot visualize it. We do have a Grizzly Mill....with indexing: G0619 6x21 vertical mill. We've never done anything with a boring bar...an idea to possibly try. Our finish required is not super important...just can't have a real rough finish or the part will not have great contact with the pot and the conductivity will not be as efficient.

In that case I would definitely go with a fly cutter / boring bar.

[mekanik]

Hi
As per Rufe0
To be honest for the application intended the boring bar option is the only way to go, you can then offer up the pot to make sure you are getting a full mating surface adjusting cutting radius to suite.
Regards
Mike