New build, looking for info on milling aluminum

[Michael Simpson Virgina]

OK I have a new build called the KRMx02. Its a sweet build and very rigid. I have done a little aluminum machining and it worked pretty good.

I am using a router so the speeds start at 8K. Here is a little vid of a part for one of my projects.


http://www.youtube.com/watch?v=cRDYsnSxF08

I am using a 1/4" two flute spiral woodworking bit, and while the results were pretty good I cant help but think with the proper bit and technique I can make it even better.

Any input would be helpful as my background is not in machining or metal working. Bit types, coolant (air or liquid) would be helpful.

I have a smaller version of my new build also complete. Here is a model of it. This is my smallest build yet, and my dream machine. The actual machine is on casters and I can roll it into any room in my shop or lab.



223244

It is built out of the same monster materials as my larger KRMx02 so its outrageously rigid. It has a removable table so I can create a special table to catch coolant. This machine will go on the road for fairs, shows, and demos. I have two shows to do in April and would love to have some sort of demo milling some aluminum.

I am open to all suggestions.

[Steve knight]

the right bit on aluminum makes a big difference. you want a single flute O flute bit you also want to do a climb cut and about 14k or so on rpms. always ramp in the cut about 60ipm max on the cut really slow plunge rate say.5 ipm depth per pass is more the bit size and the aluminum and your machine. I can cut .09 in a single pass with a 1/4" O flute.

[Michael Simpson Virgina]

Where is a good place to get single O flute bits?

[Steve knight]

onsrud is the best source. http://www.hartlauer-bits.com/ is who I get them from. but they are not cheap.

[Michael Simpson Virgina]

I notice he has bits for hard and soft aluminum. What is considered hard 6061-T6? I notice he has bits rated for both. Any recomendations for a 1/4" and 1/8" cutter?

[Michael Simpson Virgina]

Never mind I found it in his catalog. Most of my aluminum stock is 80/20 surplus bars. I believe its all T6. That would put in the hard category. But I also do some of the larger aluminum angle from Home Depot. From what I have read that is probably the nasty stuff. However I have not had that much problem with it using woodworking bits.

[Steve knight]

6061 is hard and that's why you had so much luck cutting it with a regular bit. softer stuff is a real nightmare without the 0 flute. I don't lnow what one is best for both I would think. I ahve bought 1/4" from http://www.centuriontools.com/router_bits_toolcase/index.html? and they work fine but he does not carry 1/8"