Cutting Aluminum for Channel Letters

[ed_conley]

Tried to cut 0.08" aluminum for channel letters and not having much luck.

My set-up is SB w/ Porter Cable 3 1/4hp router, 1/4" single fluted Onsrud bit for aluminum, no attached coolant system, using cool air from air compressor. Tried various combinations of speed rate and spindle speed. Was told to use > 1 in/sec and 10,000 to 13,000 rpms.

Anyone cutting aluminum with same or similar set-up? Optimum speed rate/spindle speed combination? Better bit? Suggestions?

Thanks,

Ed Conley

[ron brown]

Ed,

I've had good results similar tools .7 in/sec, .015 depth a pass, cutting fluid brushed on each pass.

HTH,
Ron

[ed_conley]

Ron:

Thanks for the info, what cutting fluid do you recommend? Do I have my router (spindle) speed right?

Ed.

[ron brown]

Ed,

Just about any cutting fluid will work. I have seen many shops use lard or vegetable shorting as a cutting fluid. I used some tapping fluid for the last project I did, it is what I had.

I don't want to get into a "chipload" discussion here with feeds and speeds. The recommended speeds will be slower spindle and faster travel. You are working with a compromise and will have to live with the tools you have to work with.

Quite possibly your greatest problem will be hold-down of material.

Ron