I've heard it said that machining aluminum is like machining wood.
Ok, that's not entirely accurate, but...
I'd be inclined to cram a roughing endmill through there and take it all out
in one pass, letting the slug drop through. I'd do the same with 3/4" tool
steel given a capable machine. While you won't need a hacksaw, your arms
will probably be pretty tired by the end of the run.
How large of an internal radius (in the corners) can the application
tolerate? Obviously, the larger the rad, the larger the cutter, the heavier
the cut. You'll want less flutes as opposed to more flutes (for chip
clearance). LOTS of coolant. Your table will probably be overflowing by the
time you've finished a couple of pieces.
If your machine has a DRO, you'll have an easy time. If not, I'd be inclined
to set up a bunch of indicators or stops to make the job go quickly. 24pcs
is enough to justify a longer setup, IMHO.
Good luck and don't forget the coolant!
Regards,
Robin
"njrich" wrote in message
om...
Gentlemen,
Hope you are fine wherever you may be.
I have a job which came my way which calls for making 2"x2" square
holes in 3/4 inch aluminum plate.
I am a construction worker, carpenter, with access to a heavy
mill-drill machine and a small home shop size band saw. I have to make
24 of these square holes in separate 5" x 6" x 3/4" sections. The
tolerances are not tight. + or - .01 inches is ok.
My question is what is the best way to do this? From what I can see
there are three choices.
1. Layout the square, drill a 5/8 hole, put a hacksaw blade through
and start hacking away. Finish off
using an end mill. Of course I might need a new set of arms when I'm
done. i need a new brain already!
2. Due the same but weld the bandsaw blade through each plate and cut
using the band saw before
finishing with the mill.
3. Drill out a square shape formed by a series of holes using a 1/4"
drill bit and finishing with the mill.
My 3 ideas might suggest to you that I have little experience with
machining metal. And that would be
quite true. So I would appreciate your suggestions.
Thanks,
Rich
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