jwinnington
New Member
I have always hated cutting aluminum due to the fact that it clogs up the blade. There has got to be a better way. Any advise?
Cutting Aluminum
- Thread starter jwinnington
- Start date
What are you cutting it with?
And what are you cutting?
Hand saw, grinding disc, dremel, bandsaw?
If using a cutting disc, you should be able to buy aluminium specific blades.
If using a handsaw or bandsaw, use a light spray on lubricant, in Australia, RP7 is generally used.
You can also use a wax based compound,(I cant remember the name), applied to grinding discs and then used to cut.
Don't ever grind aluminium on a bench grinder as the wheel clogs and may explode.
And what are you cutting?
Hand saw, grinding disc, dremel, bandsaw?
If using a cutting disc, you should be able to buy aluminium specific blades.
If using a handsaw or bandsaw, use a light spray on lubricant, in Australia, RP7 is generally used.
You can also use a wax based compound,(I cant remember the name), applied to grinding discs and then used to cut.
Don't ever grind aluminium on a bench grinder as the wheel clogs and may explode.
jwinnington
New Member
I use a jigsaw. As far as cleaning up the edges, should i use a hand file? My project needs some TLC to make it pretty
Skyler101
Sr Member
You can get special blades for your jigsaw that work really well. I use a blade that is rather widely spaced, and it tears threw aluminium! Just wear safety glasses, as the pieces go everywhere, and it hurts when a little speck gets caught in your eye!
Now if I could find out a way to cut aluminium tubing without marking it with my tube cutter, I would be a very happy man!
Hope that helps...
- Skyler101
Now if I could find out a way to cut aluminium tubing without marking it with my tube cutter, I would be a very happy man!
Hope that helps...
- Skyler101
In most cases when making a finished edge, you should cut shy of the line and finish it with a file. Correct filing is an art by itself. It is NOT sawing away back and forth, but an angled movement designed to have the teeth of the file work best. I'm certain there are youtube video's on the process. If you want two identical pieces, clamp them in a vise between two pieces of angle iron, aligned with the finished line and use the angle iron as a guide to keep the file flat.
The issue with aluminum is when it gets hot it will clog the blade. At work we mist the blades with a cheap liquid hand soap to keep it cool. As for grinders never use a grinding wheel on aluminum it will clog the grain and then expand when hot which can result in the wheel exploding, instead use a sanding drum or one of the wheels with the flaps of sand paper..
Dracosfire83
Well-Known Member
I had a lot of good experiences cutting aluminum with a low speed setting and I also like to cover the cut line with clear packaging tape (acts as a lubricant keeping the blade clean and cool).
Hi Jwinnington
Aluminum comes in many flavours.
2 very common type are 5052 and 6061
5052 is mainly used when you want to bend the material. You will find that it doesnt crack as easily as compared to other types.
Because of this characteristic you may find that it "gums" up your cutters/blades more so that 6061 unless you have the correct spindle speeds/feed rates etc.
6061 is a common type used in machining/milling/turning
If you are buying sheet material you might want to ask your metal supplier which one you have been getting...
If its 5052 you might want to give 6061 a try and see if you have any better luck.
Take care
Aluminum comes in many flavours.
2 very common type are 5052 and 6061
5052 is mainly used when you want to bend the material. You will find that it doesnt crack as easily as compared to other types.
Because of this characteristic you may find that it "gums" up your cutters/blades more so that 6061 unless you have the correct spindle speeds/feed rates etc.
6061 is a common type used in machining/milling/turning
If you are buying sheet material you might want to ask your metal supplier which one you have been getting...
If its 5052 you might want to give 6061 a try and see if you have any better luck.
Take care
Awesome info. I've always wonder what was up with the different aluminum varieties.
jwinnington
New Member
This was definitely the right place to ask this question. I make aluminum brackets a work often enough that I should know more about this than I really do. But all that requires is the metal chop saw and a drill. When I drill aluminum, I have always noticed that the bit will travel a little and the hole is never exactly where I wanted it. (I usually use 1/4" to 1/2" thick pieces). So I started pre-drilling the holes with a much smaller bit and work my way up. Works better but eh. The project that I am working on now which prompted this thread is the part which attaches Boba Fett's EE-3 to the butt stock. I currently have a cast piece and it will only be a matter of time before it breaks. My luck it will be during a troop. I did cut it a little big so I can file it down. I was going to use the grinder wheel but not now. Thanks for the advise.
When I cut tubing, I've always put masking tape around where im cutting and I use a plumbers type cutter that has a roller wheel on it. I don't know if they are all like that or not.
I also never knew there was different types of aluminum.
You have all been very helpful. Thank you.
When I cut tubing, I've always put masking tape around where im cutting and I use a plumbers type cutter that has a roller wheel on it. I don't know if they are all like that or not.
I also never knew there was different types of aluminum.
You have all been very helpful. Thank you.
