Gatorfoam with AL on one side

[itoolfred]

Having troubles with edge quality on Gatorfoam edge quality. I have seen the archived post:
http://www.talkshopbot.com/forum/messages/29/23955.html

Mostly I'm interested in bit part numbers and suppliers.

Paco you had good results, but I didn't see a bit number.
Thanks,
Fred

[Brady Watson]

The key is to do it in 2 passes. The 1st pass MUST suck up ALL the AL chips to keep it from eating the sides of the softer Gator. The 2nd pass can be done in one pass.

You have several choices. The AL should be cut with a single spiral O-flute, ideally with a ramped cutter entry option. Contact your local Onsrud dealer or MSCDirect.com to find the right tool. The foam cuts nicely with either the same single O-flute OR a 3-flute (52-624 I believe...might be a 2 flute O) OR a 4-flute standard end mill. The less flutes you have on the tool, the slower you can go before the foam blows out/pulls away from the face. A 4-flute end mill is good up to around 10 IPS in Gator - IF you have good hold-down.

-B

[itoolfred]

Brady,
Thanks for the quick reply. I'll report back as soon I get the bit in and give a try.
Fred