Machining aluminium bar

[Red Line Components]

solid aluminium bar 300mm x 30 x 75. Need to cut a 33mm square notch in the bar. I have tried drilling then sawing and filing and (apart from being bored) the results are poor. Is there a better way?

[Tony Martyr]

Handworking and machining of aluminium alloys requires techneque gained by expereince.

You can get beautiful results but you need to prevent the tool from building up swarf on the cutting edges. A file will give a rough torn surface if you don't keep cleaning the teeth. Use kerosine as a lubricant or coolant/cutting fluid and constant clearing of swarf. The best way is to use a milling cutter on a lathe or milling m/c but a file, plus time and care gets good results

[Red Line Components]

Thanks Tony, I dont mind finishing carefully by hand although its hard to get the surface finished flat. Can a pillar drill be used to mill ?

[Peter Carmichael]

No. A pillar drill can't take the side forces required for milling. You need a mill.

[Foxy Smith]

Even a very basic router as used for woodworking can be used to good effect for machining aluminium. You need to use carbide bits and only cut a small amount at a time but the results can be very good. Full face mask is a good idea also.

[Bob Simon]

re; cutting lube

 

FWIW...A bit of Crisco slathered on with a paint brush will help when machining gummy aluminums such as 2024 and 6061. Works well for surface grinding too!

 

-Bob

94 HPC VX

 

[Alex Wong1697456877]

steel wool tidies it up much more effectively than a file.